System description

Title: Compressed air system DocID: DAAB863065

Revision: -
Created by: Peter Sjöblom / 11-Feb-2006 Status: Approved
Approved by: Solomon Essuon-Bonney / 18-Dec-2006 Pages: 1 (5)
Power Plants Project: P/06020 - Kampot Power Plant
Description: System description

Compressed air system

Table of contents
1. Compressed air system ...................................................................................2
1.1 General ........................................................................................................2
1.2 System design ............................................................................................2
1.3 Control/monitoring .....................................................................................2

2. Subsystems.......................................................................................................3
2.1 Starting air system .....................................................................................3
2.1.1 Design................................................................................................................. 3
2.1.2 Function .............................................................................................................. 3
2.2 Instrument/Work air system ......................................................................3
2.2.1 Design................................................................................................................. 3
2.2.2 Function .............................................................................................................. 3

3. System components.........................................................................................4
3.1 Instrument air unit ......................................................................................4
3.2 Starting air unit ...........................................................................................4
3.3 Starting air bottle........................................................................................5

Reference documents Reference Document id

Main flow diagram (T) 7A 033 01 DAAB591375
Engine instruction manual 7A 02 02
PI diagram (TSA 901) 7A 033 01 02 180284-14
PI diagram (TCA 901) 7A 033 01 03 WD06210
Dimensional drawing (TSB 901) 7A 033 01 04 2-211-01850C
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1. COMPRESSED AIR SYSTEM

Reference Main flow diagram (T)

1.1 General

 NOTE!
For list of system and unit ALARMS, please refer to binder 2A 01 Plant operation.
It includes the alarm description, possible reasons for the alarm and step-by-step
actions in an alarm situation.

The compressed air system provides the engine with compressed air needed for
start-up (30 bar). It also supplies working and instrument air for auxiliaries and
for maintenance and cleaning purposes (7 bar).

1.2 System design

The complete system consists of components installed on the engine and
external equipment installed in the plant.
For information regarding the equipment supplied as built-on-engine, refer to
the Engine instruction manual, section 21 “Starting air system”.
The external compressed air system can be divided into the following
subsystems:
 Starting air system
 Instrument/Work air system
These subsystems are described in more detail later.

1.3 Control/monitoring
Local control panels involved in the compressed air system:
 Starting air unit ........................ BLA 901
 Instrument air unit ................... BLB 901
The supervision of the system includes several units and a number of air
vessels.
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2. SUBSYSTEMS
2.1 Starting air system
Reference: Main flow diagram (T)

2.1.1 Design
The main components of the starting air system are the starting air compressor
unit and the starting air bottle. They are installed off the engine. The system is
also equipped with drain valves located in several places in the system.
The starting air compressor unit can also act as a backup for the
instrument/control air units in case of failure or if the consumption of
instrument/control air is momentarily high. For this purpose, a pressure-
reducing valve and a safety valve are installed in the interconnection pipe of the
starting air unit.
2.1.2 Function
The main function of the power plant’s starting air system is to supply the
engine with a sufficient amount of compressed air to permit a safe and reliable
start.
The starting air compressor unit increases the pressure of the air. The air is
directed from the compressor unit to the starting air bottle, from which it
continues to the engine through an electrically operated valve. The engines are
started by admitting the compressed air directly into the engine cylinders. The
starting air system requires an air pressure of 15 to 30 bar. The engine is
started by pressing a start button located on the control panel or from the WOIS
workstation.

2.2 Instrument/Work air system

Reference: Main flow diagram (T)

2.2.1 Design
The instrument air system (or work air system) is a separate system supplying
instrument air (7 bar) to all pneumatic control and safety devices used in the
plant.
To get more flexibility in the installation, the starting air compressor and the
instrument air compressors are interconnected. This enables the starting air
unit to act as a backup unit for the instrument air compressor unit in case of a
failure or if the air consumption has momentarily increased. For this purpose, a
pressure-reducing valve is installed in the interconnection pipe mounted on the
starting air unit. In case of a malfunction in the pressure reduction unit there is
a safety valve installed to protect the instrument air system from the effects of a
too high pressure.
2.2.2 Function
The compressed air that comes from the instrument air compressor unit is
stored in an air receiver until it is distributed to different consumers via a dryer
and a filter. The instrument air compressor unit should operate continuously,
producing dry compressed air of high quality. This air is needed for control- and
instrumentation equipment in the power plant and as working air for
diaphragm pumps, blowguns and other equipment using compressed air.
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3. SYSTEM COMPONENTS
The system components described in this section are mainly those components
or units installed outside the genset.
The following units are included:
 Instrument air unit ................... TCA 901
 Starting air unit ........................ TSA 901
 Starting air bottle...................... TSB 901

3.1 Instrument air unit

Reference PI diagram (TCA 901)

 NOTE!
The instrument air unit is manufactured by Gardner Denver/Tamrotor. Please
refer to the information supplied by the manufacturer (in binder 7A 033 01).

The instrument air unit comprises one screw compressor, an air receiver and a
refrigerated air dryer. The compressor, receiver and refrigerated air dryer unit
are built on a steel frame.
The unit is equipped with control panels and necessary accessories such as
starters, suction and outlet filters, pressure switches, pressure gauges and
safety valves.
Main components on the unit:
 electrically driven air compressor
 compressed air receiver
 refrigerated air dryer
 filter for removal of oil, water and particles
 control panels

3.2 Starting air unit

Reference PI diagram (TSA 901)

 NOTE!
The starting air unit is manufactured by SPERRE Industri A/S. Please refer to the
information supplied by the manufacturer (in binder 7A 033 01).

The starting air unit consists of the following main components:

 electrically driven compressors
 control panel
 oil and water separator
 air coolers (built on the compressors)
 pressure reducer for control air
 steel frame
The starting air unit consists of two air-cooled compressors, one in operation and
the other in standby. Both compressors are electrically driven.
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The compressed air is cooled in two steps. First by an intermediate cooler

between the compressing steps and then by an after-cooler before leaving the
compressor unit.
Normal air always contains water vapour, and hence water moisture
precipitates when the air is being compressed. Moreover, a small amount of oil
always contaminates the compressed air and originates from inside of
compressor cylinder. Therefore, compressed air must be separated from oil and
water in an oil and water separator before it leaves the starting air unit.
The compressor automatically starts when the pressure drops to about 22 to
24 bar (depending on the set point) and stops at 30 bar. A low-pressure alarm
signal is activated at 18 bar. The starting air unit is also equipped with
connections for control air at 7 bar. A pressure reducer controls the outgoing
pressure.

3.3 Starting air bottle

Reference Dimensional drawing (TSB 901)

The starting air bottle has to store sufficient amount of compressed air at 30 bar
to ensure at least three start attempts. The size of the starting air bottle is
2000 l.
The starting air bottle is equipped with a draining valve as well, because
condensate has to be separated from the air before it is injected into the engine
cylinders.
The starting air bottle has the following connections and components:
A = Inlet
B = Outlet
C = Drain
Ab = Pressure gauge
Ae = Safety valve

Figure 1 Starting air bottle and valve head.