Design Class Detail
Utilities Instrument Air and Nitrogen
Systems
Capacity
Design
Item
Class 1
Instrument air Instrument air demand
capacity (all consumers including
intermittent users)
+10 % margin
Instrument air dryer Instrument air demand
(all consumers including
intermittent users) +10%
margin
Instrument air Buffer capacity based on
receiver vessel Instrument air pressure
drop from operating
pressure to the minimum
pressure (4.2 barg
(61 psig) at the user)
With priority air in
service if segregation is
in design
5 min
Nitrogen generation Nitrogen Normal
capacity continuous operating
demand + 10% margin
On site liquid Based on maximum of
nitrogen storage a. 1 week normal
demand
b. 8Hrs of peak
consumption
Vaporiser capacity Steam heated
based on class 1 flow +
intermittent demand
DEP 00.00.07.95-Gen., February 2014
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PROJECT Date
Design Class
Class 2 Class 3
Instrument air demand Instrument air demand
(all consumers including (all consumers including
intermittent users) + 30% intermittent users) + 30%
margin margin
Instrument air demand (all Same as class 2
consumers including
intermittent users) + 30%
margin
Buffer capacity based on Buffer capacity based on
Instrument air pressure Instrument air pressure
drop from operating drop from operating
pressure to the minimum pressure to the minimum
pressure (4.2 barg (61 psig) pressure (4.2 barg
at the user) (61 psig) at the user)
Consider shedding of
Consider shedding of load if load if it is in design.
it is in design.
5 min < receiver capacity >10 min up to 15 min
< 10 min
Nitrogen Normal operating Nitrogen Normal
continuous demand continuous operating
(+ 20% margin demand (+ 30% margin
Based on maximum of Based on maximum of
a. 1 week normal a. 1 week normal
demand demand
b. 24Hrs of peak b. 24Hrs of peak
consumption consumption
based on class 2 flow+ based on class 3 flow+
intermittent demand intermittent demand
Page 1 of 6
 Design Class Detail
Utilities Instrument Air and Nitrogen
Systems PROJECT Date

Capacity Utilization
Design Design Class
Item
Class 1 Class 2 Class 3
Compressor sparing No spares Sparing= N+1 Sparing=N+2 minimum

Instrument Air Dryer No spares Sparing = N +1 Same as Class 2

Sparing

ASU sparing 1 x 100% plus back up 2 x 50% plus back up 2 x 100% plus
supply provision supply provision back up supply provision

ASU feed air N+0 N+1 N+1

compressor sparing
(applicable for
separate feed air
compressor)

On site liquid N2 1x100% tank 2x50% tanks 2-100% tanks or 3-50%

storage sparing tanks depending upon
plant size

Vaporizer sparing N+0 N+1 N+1

Or
Atmospheric vaporizer
N+0 with one spare
section/module (to
facilitate periodic
defrosting)

DEP 00.00.07.95-Gen., February 2014

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Page 2 of 6
 Design Class Detail
Utilities Instrument Air and Nitrogen
Systems PROJECT Date

Expandability
Design Design Class
Item
Class 1 Class 2 Class 3
Instrument air
compressor / dryers No space provisions for Tie-ins for header Tie-ins for header
any future equipment extension. No additional extension. Space
plot space to be reserved provisions for one new
for future compressor and compressor and dryer
dryers.

DEP 00.00.07.95-Gen., February 2014

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Page 3 of 6
 Design Class Detail
Utilities Instrument Air and Nitrogen
Systems PROJECT Date

Operability & Maintainability

Design Design Class
Item
Class 1 Class 2 Class 3
Instrument Air All electric, with bus Combination of electric, and Same as class 2
compressor driver segregation steam drivers with N drivers UPS on:
types on steam or all electric with
 Compressor PLCs
segregated bus and feeder.
 Master pressure
Emergency compressor
control package
provided.
 Governor (if electric)
Dryer PLCs
UPS on:
 Compressor PLCs
 Master pressure control
package
 Governor (if electric)
Dryer PLCs
Instrument air No online dew point Online dew point monitoring Online dew point
quality monitoring. monitoring. on the common header monitoring on the
common header as well
as individual drier outlet.
Instrument Air Oil removal by filtration Oil free compressor Oil free compressor
Compressor type when oil injection type
compressor is applied

Compressor lube oil Vendor Standard Shaft driven lube oil pump Shaft driven lube oil
system + one electric driven pump + one aux lube oil
auxiliary lube oil pump pump either steam driven
or electric on emergency
power
Intercooler design Vendor Standard Back up cooling water Same as class 2
source (i.e., firewater) in
case of loss of cooling
water
Compressor Vendor standard Local instrumentation: Local and DCS indication
Monitoring and of:
Control Surge / loading  Inlet and outlet  Inlet and outlet
pressure and pressure and
protection temperature of each
temperature of each
stage stage

Surge / loading protection Surge / loading protection

Master pressure controller Master pressure

controller (sharing
(sharing compressor
compressor loading)
loading)
vibration monitoring

DEP 00.00.07.95-Gen., February 2014

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Page 4 of 6
 Design Class Detail
Utilities Instrument Air and Nitrogen
Systems PROJECT Date

Operability & Maintainability

Design Design Class
Item
Class 1 Class 2 Class 3
Segregation Segregation of plant air If tool air is supplied from IA Tool air completely
from IA and with segregated and supplied
required backflow Separate tool air piping with with separate/ mobile
protection auto cut off at pressure. compressor
Segregation of priority air
Tool air piping is Auto closing of feed air in from non priority air
separate from main the case of feed air to ASU supply lines with auto
instrument air piping N2 generation. closing isolation valves
Instrument air Single header Double header or looped Double header in the
supply header header in the common common areas
areas Double header within the
Single header within the process units (For critical
process units process, if affected
Flow meters on main complete plant shutdown)
header only
Flow meters on main
branches
Nitrogen facility Bulk supply from vendor, Own generation facility to Own generation facility
storage and vaporization meet normal demand On site liquid nitrogen
at site (can be from generation for back up
vendor as well) Or Back up from bulk supply
N2 generation system at Or piped from supplier if
site if no reliable supply available.
from vendor is available.
Nitrogen quality No on line O2 analysers On line O2 analyser for N2 On line O2 analyser for
monitoring purity N2 purity
Sampling and off line
tests
Dryer control Local control PLC based DCS based control DCS based control

Standard on/off valves Standard on/off valves

rather than 3-4 way valves. rather than 3-4 way
valves.

DEP 00.00.07.95-Gen., February 2014

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Page 5 of 6
 Design Class Detail
Utilities Instrument Air and Nitrogen
Systems PROJECT Date

Energy Efficiency
Design Design Class
Item
Class 1 Class 2 Class 3
Air compressor For steam driven Same as class 2
drivers compressors, avoid
condensing steam turbines

Incorporate compressor
load sharing master
controller with automatic
suction throttle control
Air compressor type Multi stage compression to: Same as class 2
 Reduce power losses
 Increase efficiency
Air dryer type Heatless regeneration Heated regeneration- Heat of compression for
Electric regeneration (back up
heater may be required)
Or
Heated regeneration- LP
steam

ASU plant power Not considered. No power recovery in cold Cold box- power recovery
recovery box with expander

Definitions:

Intermittent users = utility air, tool air, air to operate Clyde units for transfer of catalyst, etc.

Receiver capacity – on loss of 100% air, the time for the receiver pressure to drop from minimum
operating pressure to minimum allowable air pressure to operate actuators in the plant

Abbreviations:

LP: low pressure

PLC: Programmable logic controller

DEP 00.00.07.95-Gen., February 2014

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Page 6 of 6