COMPRESSED AIR SYSTEM

1.0 INTRODUCTION
This document covers Compressed Air System description, design philosophy for various
components of the system and design philosophy for Control and Operation system for 1 x
600 MW.
2.0 CODES AND STANDARDS
The applicable codes and standards for various major equipment in Compressed Air System
are given below. Latest editions of the following standards will also be used.
TEMA - Tubular Exchanger Manufacturer's Association
ASME - American Society of Mechanical Engineers
IS - Indian Standards
VDI - Verein Deuscher Ingenieure
RMS - Reputed manufacturers standard

3.0 DESCRIPTION OF ALTERNATIVES
The Compressors for both instrument air and service air system are selected based on the
following three (3) alternatives.
3.1 Option 1
Four (4) Nos. identical, two (2) Nos. instrument air (1 working +1 standby) and two (2) Nos. (1
working +1 standby) service air, non-lubricated screw compressors, including after cooler,
silencer and other accessories. Flow diagram for this option is furnished in exhibit 1, Sheet 1
of 3.
3.2 Option 2
Two (2) Nos. instrument air (1 working + 1 standby) non-lubricated screw compressors,
including after cooler, silencer and other accessories and two (2) Nos. (1 working +1 standby)
service air, lubricated screw compressors with oil filters, including after cooler, silencer and
other accessories. Flow diagram for this option is furnished in exhibit 1, Sheet 2 of 3.
3.3 Option 3
Three (3) Nos. identical, one (1) No. instrument air compressor working, one (1) No. service
air compressor working and one (1) common stand by for instrument and service air, non-
lubricated screw compressors, including after cooler, silencer and other accessories. Flow
diagram for this option is furnished in exhibit 1, Sheet 3 of 3.
3.4 Comparison of Alternati ves
3.4.1 Non-lubricated compressor (shaft seal system) The lubrication system provides lubrication
only to crankshaft bearings, crank pins, cross head pin and cross head guides. The piston
rings and packing rings are not lubricated by oil but only by using self-lubricated materials
such as Teflon. Compressor major constructive parameters (speed, stroke, cylinder, piston
and piston rod) are specially selected and designed to enhance ring life and ensure
compressor performance.

3.4.2 Lubricated compressor (oil flooded) The lubrication system provides direct lubrication to
the crankshaft bearings, crank pins, cross head pins, cross head guides, packing rings, and
piston rings.

3.4.3 For instrument air application non-lubricated screw compressor is preferred considering three
key failure risks associated with lubricated compressor systems:
- that temperature rise will increase oil carry-over through the filters;
- that higher temperatures will severely reduce the lifetime of activated carbon filters; and
- that if filters become blocked because they are not changed in a timely manner, the filter
will be bypassed and oil will enter the process.
Since permissible oil content in instrument air is of the order <0.01 mg/Nm
3
and under no
circumstances the same can be relaxed, non-lubricated type air compressors are selected for
the application.




3.4.4 For service air application lubricated screw compressor can suffice since there is no string out
limit on permissible quantity of oil in the service air.
A combination of oil-removal systems - oil separator, oil removal filters are adequate to meet
requisite quality of air. Oil filters are available which can filter oil upto <0.01 mg/m
3
from
compressed air that meets the requirement of instrument quality air.
3.4.5 Option 1
a) This option meets the requirement of instrument air as well as service air application.
b) In this option service air compressor being non-lubricated type can operate as standby for
instrument air application in case of any emergency.
c) Cost of this option would be the highest amongst all three (3) options.

3.4.6 Option 2
a) This option meets the requirement of instrument air as well as service air application.
b) In this option, instrument air compressors and service air compressors will be independent.
However 100% standby is available for either of the systems.
c) Cost of this option would be lesser than that of option 2.

3.4.7 Option 3
a) This option meets the requirement of instrument air as well as service air application.
b) In this option, 100% standby is not available for either of the services. The standby
compressor would be common, which would be prioritized to cater to standby requirement of
instrument air which is critical.
c) Cost of this option is expected to be higher than option 2 and lower than that of option 1.

3.5 Conclusion
In view of more reliability option 2 is recommended for installation, though its cost could be
marginally higher than that of option 3.
4.0 DESIGN CRITERIA
4.1 DESIGN INPUT
Design ambient temperature : 42.8C
Design relative humidity : 75%
Site elevation : 215 M above MSL

4.2 ASSUMPTIONS
4.2.1 The compressor will be selected considering the maximum air requirement during various
operating conditions of the plant.
4.2.2 Operation of air compressors regarding selection of operating and stand by compressors and
also method of starting of stand by compressor will be as per manufacturers practice.
4.2.3 Compressed air requirement of ash handling system, mill reject system and coal handling
plant are not considered and would be included in respective packages in which necessary
independent systems as required would be provided. However service air requirement for coal
handling plant is considered in this system.
4.3 SIZING CRITERIA
4.3.1 Based on the Instrument air and service air requirements capacity of compressor is selected.
Calculation for compressor capacity is furnished in Annex-II and III.
The capacity of compressors has been considered as given below:
a) Instrument air requirement : 1800 Nm/hr


b) Service air requirement (same as Instrument air compressor) : 1800 Nm/hr

4.3.2 The design pressure of the compressed air system is 9 Kg/cm
2
(g). The pressure required for
service air and instrument air consumers is 8.1 Kg/cm
2
(g). However, in case of emergency,
the minimum instrument air pressure required at the consumer point would be 5.5 Kg/cm
2
(g).

4.3.3 Pipe sizes will be selected considering a maximum pressure drop of 0.3 kg/cm
2
in the pipeline.

4.3.4 Compressor Air Quality:
Instrument Air Quality will comply with ISO 8573.1, quality class 2.2.1.

Service Air Quality will be of a general quality with the majority of water/moisture removed and
filtered to ISO 8573.1, quality class 3.2.4.

4.3.5 Noise Level:
The air compressors will be designed for a maximum normal operation sound level of
85 dBA at a distance of 1.0 m from machine. Required acoustic enclosures will be provided to
achieve the desired noise level.

5.0 DESCRIPTION OF SYSTEMS
The compressed air system comprises of both instrument air system and service air system.
Instrument air is required for the various pneumatically operated valves, transmitters and
instruments in the power plant and other users requiring dried air, while service air is required
for boiler, turbine and other utilities as well as general service air for cleaning purpose.
Instrument and Service air requirements will include but not limited to following areas:
Instrument Air requirement: Steam Generator, Steam Turbine Generator, Balance of Plant
area, All Common services and maintenance workshop.
Service Air requirement: Steam Generator & ESP area, TG building, Service building, ETP,
DM plant and CPU regeneration area, CW pump house Raw water & Clarified pump house,
Fuel oil unloading, Storage and forwarding areas, maintenance workshop, DG set room and
fire station. Refer Distribution drawing. No. 00-3170830002-M-038 & 00-3170830002-M-039.
5.1 BRIEF DESCRIPTION OF SELECTED COMPRESSED AIR SYSTEM
Refer exhibit 1 sheet 2 of 3, the plant will be provided with compressed air for both
pneumatic controls and for general services requirement the compressed air system would
include:
5.1.1 Two (2) Nos. (1 working +1 standby) instrument air compressors will be provided. These will
be non-lubricated screw type and complete with suction filters, after cooler, silencer and other
accessories.
5.1.2 Two (2) Nos. (1 working +1 standby) service air compressors will be provided. These will be
lubricated screw type and complete drive motors with oil filters, after cooler, suction filters,
silencer and other accessories.
5.1.3 Two (2) Nos. (1 working +1 standby) Air Drying Plants heat of compression type with all
inter connecting piping, valves, fitting etc for instrument air shall be provided.
5.1.4 Two (2) Nos. air receivers, (one (1) instrument air +one (1) service air).
5.1.5 All interconnecting piping, valves, fittings, supports/hangers, central air tubing (complete with
valves and fittings between air receiver, compressor and local panel for each compressor),
cooling water piping and valves for safe and satisfactory operation of air compressors.
5.1.6 Controls & interlocks.
5.1.7 All instruments including the dew point meter with suitable sampling connection and isolation
valve at the common outlet of the ADP.
5.2 BRIEF DESCRIPTION OF THE EQUIPMENT
The compressed air system consists of the following components/equipment.



5.2.1 Air Compressor
The instrument air compressor is designed to take care of the instrument air requirement
(excluding the compressed air requirement of Ash Handling System and Coal Handling Plant).
The capacity of instrument air and service air compressor would be 1800 Nm
3
/hr. Delivery
pressure will be 8.8 Kg/cm
2
(g) at ADP outlet. Instrument air compressor would be non-
lubricated screw type. Each compressor would be designed to deliver the free air delivery
(FAD) capacity at the required delivery pressure.
The FAD capacity of the compressor has been fixed considering for 42.8C DBT and 75% RH.
In addition to the instrument and service air requirements of SG / TG, the instrument and
service air systems would meet the instrument air requirements of the various systems in
BHEL scope.
Each compressor will be provided with inter cooler and after cooler. These are horizontal,
water-cooled cooler of shell and tube design and capable of cooling the rated compressed air
capacity of the compressor. The after cooler outlet air temperature is not more than the
ambient temperature.
Air compressors would be designed for continuous operation with high efficiency to satisfy the
performance requirement.
The continuous motor rating (50
0
C ambient) will be at least ten percent (10%) above the
maximum load demand of the driven equipment under the entire operating range.
When the driver is not directly coupled to the compressor, due consideration would be made
for losses in power transmission, in addition to the above margin.

5.2.2 Air Drying Plant
There shall be two (2) air dryers (1 working +1 standby) each to suit the capacity of air
compressor. Air drying plant (ADP) will be of heat of compression desiccant type, drying by
adsorption method. The quality of outlet air from the ADP will be in accordance with The
Instrument Society of American Standard S7.3 "Quality standard for instrument air". The same
will be as follows:
Dew point at the outlet of the drying plant will be minus (-) 40C at Atmospheric pressure and
(-) 20C in pressure condition.
Dust particle size in the instrument air will be limited to ten (10) microns.
Desiccant will be silica gel / activated aluminium or as per manufactures standard.

5.2.3 Air Recei vers
The capacity of each of the two (2) air receivers (one (1) instrument air receiver and one (1)
service air receiver) will be 10 m
3
(Nominal).
The air receivers would be vertical self supporting cylindrical vessels with supporting legs for
resting on the foundation.



5.2.4 Intake Filter
Dry type suction air filters would be provided at the compressor inlet to prevent dust and dirt
from entering casing. The filtering efficiency would be 90% down to ten (10) microns. Sound
suppressing characteristics would be considered in the filter design.
5.2.5 Piping and val ves(within compressor house)
All interconnecting compressed air piping will be MS galvanised conforming to IS: 1239 (Part
I) (Heavy Grade). All cooling water air piping will be MS conforming to IS: 1239 (Part -I)
(Heavy Grade). Fittings for air piping will be conforming to IS: 1239 Part - II and Grade
equivalent that of parent pipe grade. Compressed air piping from air compressor to after
cooler and other lines handling hot air would be suitably insulated so as to restrict surface
temperature to 60C. The pipe joints would be screwed coupling type for sizes up to 50NB and
above 50NB the same would be flanged.
Moisture traps at strategic locations would be provided in the distribution network.
6.0 LAYOUT
Air compressors and air driers would be located indoor at ground floor of Air washer building.

Two (2) nos instrument air compressors and two (2) nos service air compressors are kept in
air washer building at EL. 0.0 M near TG building near A row. The compressor room will be
provided with necessary crane to handle equipment/components during maintenance. Air
receivers will be placed outside the building. ADP equipment would be skid mounted and
located indoor. Refer GA of compressor room drawing no. 10-3170830002-M-114.

7.0 CONTROL AND OPERATION PHILOSOPHY
7.1 Two (2) compressors will provided for Instrument air system. Similarly two (2) compressors will
be provided for Service air system. Operation controls of compressors will be as given below.
7.2 Instrument air compressors: Out of two compressors one will be working on load-unload mode
and another will be on start-stop mode. Each compressor will be controlled by microprocessor
based control panel mounted on air compressor. Continuous run load-unload control and
Automatic start / stop control shall be based on the manufacturers standard. The compressor
will be operated normally either from the local microprocessor panel or remote DDCMIS
through necessary gate way. Necessary hardwire signals, interface will provided for control
functions.
7.3 Service air compressors: Operation of these compressors will be similar to Instrument air
compressors.
7.4 Normally one (1) drier will be operating and one (1) will remain standby for each system.
Change over to standby drier from the operating drier will be manual. The drier will be
operated from local control panel or from remote DDCMIS.
7.5 The control system will be capable of communicating with the central control room through
converter gateway for achieving functions of remote control and monitoring.
7.6 Important safety interlocks
The following safety interlocks shall be provided for each compressor:
a) Compressor lube oil pressure low (alarm and trip)
b) Compressor lube oil temperature high (alarm and trip)
c) Compressor air temperature high at 1
st
/2
nd
stage discharge (trip)
d) Air pressure in common header high and low (alarm)
e) Air temperature at after cooler inlet high (alarm and trip)
f) Compressor start only after coolant flow is established.
g) Cooling water flow to compressor low (trip) provided outside the compressor skid.
h) Over loading of motor (trip)Any other protection recommended by manufacturer.

7.7 Remote Monitoring & Control


In addition to the above and Manufacturers recommended instruments following instruments
& control shall be considered for remote monitoring.
System shall operating in LAN mode.
a) Loading / unloading indication.
b) Remote start & stop.
c) 1
st
stage and 2
nd
stage discharge pressure and temperature.
d) Air pressure and temperature at after cooler outlet.
e) Motor current Direct from HT switchgear to DDCMIS (4-20mA)

8.0 TECHNICAL DATA/MATERIALS OF CONSTRUCTION
8.1 Technical Data
8.1.1 Instrument Air Compressors
Description Instrument Air

Compressor capacity : 1800 Nm
3
/hr.

Compressor discharge
Pressure : 9 kg/cm
2
(g)

Number : Two (2) (1W +1S)

Type : Non-lubricated, screw, water- cooled, two stage

Inter-cooler & after cooler : As per TEMA-C/IS: 4503/ASME Sec. VIII /
Manufacturers standard.

Accessories : Moisture separator, Intake air filter, silencer, inter
cooler and after cooler.
8.1.2 Service Air Compressors
Description Instrument Air

Compressor capacity : 1800 Nm
3
/hr.

Compressor discharge
Pressure : 9 kg/cm
2
(g)

Number : Two (2) (1W +1S)

Type : lubricated, screw, water- cooled, two stage

Inter-cooler & after cooler : As per TEMA-C/IS: 4503/ASME Sec. VIII /
Manufacturers standard.

Accessories : Moisture separator, Intake air filter, Oil filters, Silencer,
inter cooler and after cooler.
8.1.3 Air Dryers
Type : Heat of compression desiccant type

Number : Two (2) 1 working +1 standby for instrument air

Output capacity : to suit

Drier outlet : At Atmospheric condition: dew point (-) 40C
Pressure at instrument air
Receiver outlet : Not less than 8.3 kg/cm (g)

Max. temperature of air permitted
at outlet of air receiver : 8 to 10 C above cooling water inlet temperature.




8.1.4 Air Recei vers for Instrument Air and Service Air
Design code : IS: 2825 / IS: 7938

Capacity : 10.0 m
3


Number : One (1) for instrument air and One (1) for service air

8.1.5 Motor Rating
The compressor shall be driven by electric motor. Motor shall be sized considering the drive
losses and design ambient conditions. The motor rating will be arrived at considering 10%
over the maximum demand of the driven equipment.

8.2 The materials of construction of major equipment
The materials of construction of major equipment / Items is listed in Annex I.

9.0 REFERENCE DRAWINGS/DOCUMENTS

10-3170830002-M-004 : Plot Plan
10-3170830002-M-101 : GA of TG building 0.0 m plan


ANNEXURE I
STANDARDS APPLICABLE FOR MATERIALS OF CONSTRUCTION OF MAJOR
EQUIPMENT
(Other than compressor and drier)


Sl. No. Name of equipment Material of construction applicable standard

1 Gate, Globe, Ball & Check valves ASTM A216 Gr WCB for (>65NB) for IA & SA
ASTM B62 / IS318 Gr.2 for (< 50 NB) for
Instrument air system, ASTM A105 (<50 NB)
for service air system.

2 Piping


a) Material IS1239 GALVANISED

b) Standard (fittings) ASTM A 234 WPB GALV. For (>65NB) ASTM
A105GALV. For (<50 NB)

c) Flanges ASTM A105 GALV.

d) Gaskets TEFLON

3 Air Receivers IS-2002




ANNEXURE II
CALCULATIONS FOR FAD AND AIR RECIVER SIZING

1.0 FAD CALCULATIONS

1.1 Altitude of site, in mean sea level, meters : 215

1.2 Maximum ambient temperature in degrees Celsius : 42.8

1.3 Maximum relative humidity : 75%

1.4 Barometer pressure corresponding to the : 98.26
altitude (kPa)

1.5 Vapour pressure corresponding to maximum : 6.41
ambient temperature (kPa)

1.6 Atmospheric pressure at site (kPa) : 98.26 - [6.41x 1.0]

: 91.85 kPa

1.7 Volume of air at NTP conditions : V
N
in N m
3
/hr

1.8 Free air delivery (FAD) of the compressors : 101.303 x V
N
x 315.8
91.85 x 273

: V
N
x 1.28

2.0 AIR RECEIVER SIZING

Capacity of compressors : 1800 Nm
3
/hr
: 1800*1.28
: 2304 m
3
/hr

Method I: Air receiver capacity : 1.6*(comp. capacity/60) ^0.5
: 1.6*(2304/60) ^0.5)
: 9.91 m
3


Method II: Air receiver capacity :
(as per IS: 6206) : (1/10) x (comp.
capacity/60) : (1/10) x (2304/60)
: 3.84 m
3

Method III: Air receiver capacity :
(Considering starting time for standby compressor
to be 10 sec)
:

: 8.02 m
3
The selected Air receiver capacity is 10 m
3
.

Two (2) nos of air receiver is required
one (1) for instrument air and one (1) for service air compressor.
T x V
1
x P
A
(P
RMax
P
RMin
) 3600
10 x 2304

x 0.936

(8.3 7.5) 3600


ANNEXURE III
CALCULATION OF INSTRUMENT AIR AND SERVICE AIR REQUIREMENT
A) INSTRUMENT AIR REQUIREMENT



Capacity of Instrument Air Compressor:

Then total Instrument air requirement works out to be 12.883 Nm
3
/min continuous and
9.841 Nm
3
/min Intermittent.
Considering a diversity factor of 0.6
Margin considered for leakage/loss is 1.1
Uprating factor to be applied is 1.25
Hence, total instrument air requirement is,
= (12.883 +9.841 *0.6) * 1.25 * 1.1
= 25.833 Nm
3
/min
Instrument air compressor size selected = 30 Nm
3
/min
Note:
1.0 Instrument air indicated above for BTG area is based on assumption from similar capacity
project.
2.0 Instrument air requirement for Coal handling plant and ash handling system is part of
respective package. Hence same is not considered.

Sl. No. Instrument Air Requirement
Nm
3
/min
Continuous Intermittent
1 Boiler Area 7.276 4.552
2 Turbine Area 3.907 3.289
3 DM plant including CPU 1.0
4 CW Pump house area 0.2
5 Clarified water pump house area 0.2
6 Fuel oil unloading area 0.06
7 Fuel oil tank form area 0.24
8 CW treatment system 0.5
9 Instrumentation Lab (Estimate) 0.5
10 Electrical Lab (Estimate) 0.5
11 Chemical Lab (Estimate) 0.5

Total 12.883 9.841


B) SERVICE AIR REQUIREMENT




Capacity of Service Air Compressor:

Maximum Continuous requirement during normal operation is 3.996 Nm
3
/min.
Considering a diversity factor of 0.3
Margin considered for leakage/loss is 1.1
Uprating factor to be applied is 1.2
Hence, total instrument air requirement is,
= (3.996+51.564*0.3) * 1.2 * 1.1
= 25.694 Nm
3
/min

Service Air Compressor being supplied is of 30 Nm
3
/min capacity which is more than
adequate.
Purpose this calculation is to accertain adequacy of compressor capacity selected.



Sl. No. Service Air Requirement
Nm
3
/min
Continuous Intermittent
1 Boiler area 3.996 44.224
2 Power house 2.67
3 BOP users 4.67

Total 3.996 51.564