Comp-Air-Design-Guide by Singh
Comp-Air-Design-Guide by Singh
FOR
COMPRESSED AIR SYSTEM
12.0 VALVES 17
In addition to the compressed air being used for control (termed as Instrument Air - IA), it is
also used for purposes such as atomising fuel in a fuel gun, scavenging a fuel gun for
maintenance purposes power for driving pneumatic appliances (termed as Service Air-SA).
The aim of this design guide is to identify the compressed air requirement of major associated
equipment in a Thermal power station, Gas turbine plant and Combined cycle power plant
and to evolve guidelines for selection of design parameters of the compressed air system.
State of art
This includes a brief discussion on the practices being followed specially by Indian
consultants, namely DCL and NTPC in the selection of the various design parameters
of a compressed air system. A station capacity of two (2) units of 210/500 MW each
has been considered while working out an example on compressor sizing.
The compressor is the heart of the plant which sucks ambient air through suction
filter-cum-silencer. The compressor can be horizontal or vertical, single or multistage,
reciprocating or screw and can be air or water cooled. The compressor is driven by an
electric motor either directly coupled or through `V' belts.
When ambient air is compressed in the compressor, enormous heat will be added to
the air due to compression. The resulting air temperature may be as high as 160ºC,
which, if directly used, will be harmful to the equipment. Hence in case of a
multistage compression, the compressed air is cooled in an intercooler and after final
compression, is cooled in an after cooler. The inter and after coolers can either be air
or water cooled and if water cooled, can either be horizontal or vertical.
Immediately next to the aftercooler, a moisture separator which can be integral part to
aftercooler or separate is provided to remove the condensed moisture from the cooled
compressed air. An automatic drain trap is provided at the bottom of the separator,
which drains out periodically, the collected water.
The air, thus compressed and cooled, is stored in an air receiver before distribution.
The receiver, in addition to storage, also dampens the pulsations in air and will
condense and drain as much moisture as possible through auto/manual drain traps
provided.
From the air receiver, service air is taken to the various consumer points directly
whereas the instrument air is taken through an Air drying plant. The purpose of the
Air Drying Plant generally used in power station are of following type
2. Heat of Compression
4. Refrigerated type
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The practice of sizing of on I-A compressor for a station capacity of two units (2x210 MW) is
to consider the total continuous & intermittent requirement for each unit. Simultaneity factor
of 0.4 is considered for intermittent requirement. In addition to this a margin of 25% for
leakage, wear & tear and contingency is taken for sizing the compresses.
Service air requirement is generally less than Instrument air requirement, but compressor of
service air is select same as that of instrument air keeping in mind the contingency
requirement in case of emergency.
Wherever possible, it is advisable to provide same capacity compressors for IA & SA duties
for interchangeability and advantage of common spares.
Miscellaneous
1 Ash Handling Plant Cont 5
2 Mill Reject System Cont 1.25
3 DM Plant Cont 3
CUSTOMER REQUIREMENT
TOTAL (Cont.)
Load/unload method:
In this mode the compressor runs continuously but its capacity is controlled by
loading and unloading a set of cylinder by lifting the suction valve plates off their
seats, which is affected through an electric means. Once the desired pressure setting
in the pressure switch (s)/, these cylinders are loaded again on fall of pressure. The
Drawing `Scheme of Controlling Air Compressor' indicates a scheme where in the
capacity control is achieved in steps of 100%, 50% and 0% through the solenoid
valves SV1 & SV2 which are energised to open at set valves by means of pressure
switches installed on the outlet header of each compressor. This allows the air from
the air receivers to the unloading valves of the compressor thus unloading the
compressor 50% & 100% respectively. Similarly, the loading in steps of 50% &
100% is achieved when the solenoid valves SV1 & SV2 are closed successively.
On-off method
In this mode the compressor is started or stopped automatically depending on the air
pressure. The pressure switches mounted on each compressor outlet header give
signal to compressor motor starter thereby starting and stopping compressor motor.
a) The capacity is regulated by throttling the air inlet and at the same time, opening a
blow off valve. Under load the blow-off valve is closed and the throttle valve fully
open. The unloading device is operated by a spring loaded automatic air relay of the
In case of intermittent demand of compressed air the fall and rise in pressure will be
very rapid and in case of the ON/OFF mode the compressor motor is subject to
frequent start and stop which will naturally be harmful to the motor and cable and the
compressor will have reduced life in view of the frequent stress imposed on it.
The IS. No. IS-6206-1971 entitled Guide for Selection, installation and maintenance
of air compressor plants with operating pressures up to 10 Bars. states Automatic start
- stop operation of motor is also possible but its use shall depend upon the size of the
motor, the nature of the application, and local conditions of power supply.
a) `Dual Control' with the load/unload control being, `Main' and ON/OFF as
`Standby' shall be provided.
b) The Load/Unload system shall have both electric and mechanical means of
load/unload, the mechanical as a standby to the electrical one. In case of failure of
the pressure switch or the solenoid valve associated with the electrical system
(which is quite frequent), the air regulator path i.e. `Mechanical' control can be
opened manually through a selector, switch.
d) Loading & unloading in steps of 0%, 50% & 100% are only recommended.
e) The compressors in whatever mode of capacity control shall be able to start only
in unloaded condition.
When the boiler/turbine unit trips due to power failure the compressors also trip. But
however, compressed air is required for bringing down the essential control/trip
valves to their original position and also emergency running of regenerative air heater
air motor. These requirements are met from the air receiver.
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8.2 Analysis and Recommendation:
The following are recommended:
i) The total live I.A. and S.A. receivers(s) capacity shall be sized based on storing
ten (10) minutes of total working Instrument air compressor (s) capacity or as per
customer requirement taking into account the resultant increase in volume of air
due to fall in pressure from receiver pressure of 8 kg/cm2 (g) which being the
minimum pressure at which most of the instruments can operate.
iii) All receivers shall preferably be located outdoors, adjacent to the compressor
plant.
The air Drying Plant is needed for providing moisture free compressed air which is
required for the instrument controls. The present day air drying plant are capable of
drying air to a dew point of -40ºC. This quality of air is generally acceptable to all
the instruments and controllers.
.
(a) Blower Regenerated No loss Type Drier - The regeneration air from centrifugal
blower at low pressure is allowed to pass through an electrical heater of pre-
determined rating. The hot air which has got very high moisture holding capacity
picks up the absorbed moisture from saturated desiccant bed and vented to
atmosphere.
(i) Full flow - Hot air from last stage compression is bed into the absorber vessel
for regeneration and then same air is cooled in a specially designed combination cooler. After
cooling; this air goes through the second absorber where the moisture goes absorbed in
activated bed and dry air goes out.
(ii) Split Flow: - The main compressed air stream passes through after cooler,
then into drying section, and finally out of the dryer into the dry compressed air net. All
moisture is removed through adsorption by the silica gel powder on the glass fibre based
paper drum. The regeneration airstream by passes the after cooler and in lead is shunted into
the regeneration section. The regenerated airflow is mixed with the main flow in the ejector
nozzle.
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9.2 Analysis & Recommendation:
Earlier non-purged air flow, desiccant type, air drying plant with separate blower and
suction filter arrangement was recommended but know a days due to advent of screw
compressors in the compressed air system, Heat of compression type Air drying plant is being
asked by the customer.
The compressed air piping can either be of mild steel galvanised. It is an obvious fact
that galvanised pipes are superior to black pipes, because of its corrosion resistance. The cost
difference between a black and galvanised compressed air pipework, which are of small bore,
is very insignificant and hence galvanised piping for both IA and SA pipework are preferred.
.
a) Galvanised pipes for both IA & SA with screwed joints as per BS: 21:1973
only with Teflon tapes, if necessary.
b) For site threading a coat of zinc epoxy shall be applied both inside and
outside after due cleaning of the part.
c) The distribution piping shall be run over ground with drain points at suitable
location.
In case of auto drain traps, they get clogged due to dirt in course of time and hence do
not function properly. It, therefore, becomes necessary to provide manual bypass
arrangements.
However, in the compressor house where the piping is run in trenches, auto drain
traps with manual Bypass shall be provided.
12.0 VALVES:
The following types of valves are being used in the compressed air lines:
a) Gate valve
b) Globe valve
c) Plug valve
d) Ball valve
Intermittent - 1.5 - -
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