AIR COMPRESSOR AND DRYER

 INTRODUCTION SYSTEM
 SPECIFICATIONS
 PARTS OF THE COMPRESSOR
 COMPRESSOR FLUID CIRCUITS
 ELEKTRONIKON® GRAPHICPLUS CONTROLLER
 REGULATION
 FACTORY SETTING - WARNING ALARM & TRIP PARAMETERS
 COMPRESSOR P&I DIAGRAM
 START/STOP/ISOLATION FOR THE COMPRESSOR
 DRYER
 DRYER P&I DIAGRAM
 AIR RECEIVER TANK
INTRODUCTION :

COMPRESSOR :
A compressor is a device that increases the pressure of a substance (usually a gas)by
reducing the volume of the substance.

Uses in power plant :

There are two types of air needed in power plant. One is instrument air and the other is
service air. All control valves, pneumatic dampers, gates, guide vanes do operate by the use
of instrument air which is a dry compressed air. It is a compressed air directly coming out of
the compressor. It is used for other purposes like transmitter purging or cleaning.
Both Instrument and service air is stored in large receiver tanks so as to avoid instant air loss
incase the compressor is tripped.
SPECIFICATIONS:

Make - Altas copco

Model - ZR425-8.6
Type - Oil free screw compressor(2 stage)
Flow - 64 Nm3/min
Maximum discharge pressure - 8.6 Bar(g)
Normal working pressure - 8.2 Bar(g)
Unloading pressure - 7.6 Bar (g)
Type of cooling - Water
Cooling water flow - 22 t/h
Cooling water inlet pressure - 0.4MPa
Motor Details - 425 KW,50Hz,6.6KV,1485 RPM
Number of compressor - 4 working+1hot + 1 maintenance
standby
 PARTS OF THE COMPRESSOR

Air filter
LP compressor element
Intercooler
HP compressor element
Aftercooler
Water separator
Gear casing
Oil pump
Oil filter
Oil cooler
Silencer
Safety valve
Elektronikon controller(MK5)
Motor
 COMPRESSOR FLUID CIRCUITS
 Air Circuit
Oil Circuit
Cooling Water And Condensate Drain Circuit
Condensate Drain Water Circuit

AIR CIRCUIT :
Air drawn through filter (AF) is compressed in low-pressure compressor element (El).
The cooled air is further compressed in high-pressure compressor element (Eh) and
discharged through silencer (AS) and aftercooler (Ca).
A check valve (CV) is fitted downstream of the aftercooler. The compressed air leaves the
compressor via the air outlet (AO).
Throttle Valve (TV) AF- Air filter
AO-Air outlet
AS-Silencer
BV-By pass valve
Ca-Aftercooler
Ci-Intercooler
Co-Oil cooler
Cv-Check valve
Eh-High presser element
El-Low pressure element
MTa-condensate drain aftercooler
MTi-Condensate drain intercooler
OF- Oil filter
OP-Oil pump
OIL CIRCUIT :

Oil is circulated by pump (OP) from the sump

of the gear casing through cooler (Co). The oil
passes through oil filters (OF) towards the
bearings and timing gears.
Valve (BV) opens if the oil pressure should rise
above a given value.
Then goes to HP &LP elements , finally return
to oil sump .
Oil sump capacity 85 L
Oil type -Atlas Copco Roto-Z
COOLING WATER CIRCUIT :

The cooling water flows through oil cooler

(Co), the cooling jackets of high-pressure
compressor element (Eh) and low-pressure
compressor element (El), as well as through
intercooler (Ci) and aftercooler (Ca).
The cooling water flows also around the outlet
pipe of compressor element (El).
CONDENSATE DRAIN WATER CIRCUIT :
Two moisture traps are installed: one
downstream of the intercooler (MTi) to
prevent condensate from entering compressor
element (Eh) and one downstream of the
aftercooler (MTa) to prevent condensate from
entering the air outlet pipe.
The moisture traps are connected to
condensate drain receivers. Each drain
receiver is fitted with a float valve to
automatically drain condensate and with a
manual drain valve.
An extra moisture trap (MTb) is fitted in the
blow-off pipe to prevent moisture from
blowing through silencers (US) during the
transition from loaded to unloaded operation.
 ELEKTRONIKON® GRAPHICPLUS CONTROLLER
The Elektronikon controller has following functions:
• Automatic compressor control
• Compressor protection
• Service warning
• Automatic restart after voltage failure (disabled)
1) Approx. 25 seconds later (programmable), the compressor starts running loaded.
2) The compressor will run unloaded for 3 seconds and then stop
3) The compressor will not be allowed to restart within a programmed time (20 s) after a stop for
any reason at all.
4) At least 15 minutes under unload condition before it stopped
5) high-voltage motor, the number of motor starts is limited to 3 starts per day
6) Pressure difference between unloading and loading pressures in bar recommended minimum 0.6
bar.
NOTE : Automatic Restart After Voltage Failure – ARAVF ,If enable,
Maximum power down time 20s and compressor restart automatically without no time delay
seconds.
REGULATING SYSTEM :
The regulator keeps the net pressure within programmable pressure limits by
automatically loading and unloading the compressor depending on the air
consumption.

LOADING
If the air consumption is less than the air delivery of the compressor, the net pressure
increases. When the net pressure reaches the upper limit of the working pressure
(unloading pressure), solenoid valve (Y1) is de-energized. The plunger of solenoid
valve (Y1) moves by spring force shutting off the control air supply to unloader
(UA).
UNLOADING
When the net pressure decreases to the lower limit of the working pressure (loading
pressure), solenoid valve (Y1) is energized. The plunger of solenoid valve (Y1)
moves against the spring force opening the control air supply port to unloader (UA).
DURING UNLOADING :

1.Control pressure is vented from chamber

(1) of unloader (UA) through solenoid
valve (Y1) and chamber (3) towards the
inlet of compressor element (El).
2.As there is no longer any pressure
difference between chambers (1 and 3),
plunger (2) returns by spring force keeping
full-load/no-load valve (TV) closed and
unloading valve (UV) open.
3.Compressed air between check valve
(CV) and valve (UV) is blown off through
silencer (US). Check valve (CV) closes.
4.As vacuum prevails in intercooler (Ci),
diaphragm (4) switches to the left.
DURING LOADING :

1.Atmospheric pressure is
allowed through solenoid valve
(Y1) to chamber (1) of unloader
(UA). As this pressure is higher
than the pressure in chamber (3),
full-load/no-load valve (TV)
starts opening.
2.Intercooler pressure is
building up causing diaphragm
(4) to switch to the right. As the
pressure difference between
chambers (1 and 3) increases,
plunger (2) moves further
against the spring force until
full-load/no-load valve (TV) is
fully open and unloading valve
(UV) closed.
FACTORY SETTING VALUES FOR WARNING ALARM AND SHUTDOWN
PARAMETERS
S.NO PARAMETERS UNIT WARNING SHUTDOWN
ALARM

1 Compressor outlet pressure Bar 9 9.1

2 Intercooler pressure Bar -0.7 -0.8

3 Element 1 outlet temperature °C 210 220

4 Element 2 inlet temperature °C 65 70

5 Element2 outlet temperature °C 210 220

S.NO PARAMETERS UNIT WARNING SHUTDOWN
ALARM

9 Motor winding temp U1 °C 145 155

10 Motor winding temp V1 °C 145 155

11 Motor winding temp W1 °C 145 155

12 Motor DE temp °C 110 115

13 Motor NDE temp °C 110 115

14 Cooling water outlet temp °C 50 -

15 Cooling water DT °C 25 -
AIR COMPRESSOR P&I DIAGRAM
START
 Ensure that the permit has been cancelled and all men material removed from the
area.
 Check oil level normal in the gear box casing of the compressor .
 Ensure cooling water inlet /outlet valves should be are open and flow is established.
 Check the outlet valve of compressor , should be in open condition.
 If IAC is taken in service then at least one dryer should be charged. To charge the
dryer inlet and outlet valve of dryer should be in open condition. Ensure that drain
valve of moisture trap is in open condition. Also ensure that air receiver tank inlet
and outlet valve is in open condition.
 Ensure power supply /breaker service mode condition/local control panel
supply/emergency stop button release condition
 Switch on the compressor, press start button. Ensure direction of rotation /observe
any abnormal sound ,vibration ,loading and unloading all parameters are normal.
STOP
 Press stop button , ensure compressor stopped condition.
 Open manual drain valve and drain the condensate water .
 Cooling water inlet /outlet valve close after 15 mins.
 Keep standby condition incase of emergency time need to start.
ISOALTION
If going to take maintenance activity
Apply emergency stop button
Compressor discharge valve should be closed.
Depressurized the compressor must need to ensure before open
pressure parts.
Make proper PTW.
Isolate the 6.6 Kv power supply and ensure switch gear in rack out
condition.
SERVICE MENU IN COMPRESSOR
Function
• To reset the service plans that have been carried out.
• To check when the next service plans should be carried out.
• To check which service plans were carried out in the past.
• To modify the programmed service intervals.
SERVICES PLAN

 A number of service operations are grouped

(called Level A, Level B, etc...). Each level
represents a number of service actions to be
carried out at the time intervals programmed
in the Elektronikon controller.
 When a service plan interval is reached, a
message will be displayed.
 After carrying out the service actions related
to the indicated levels, the timers must be
reset manually.
AIR DRYER :
An air dryer is a system of equipment that is used to remove moisture present in the air,
particularly compressed air. They are important to maintain reliable operation of
downstream equipment. The dew point temperature is the temperature at which the air
becomes saturated with water vapor.

Air DRYER :
Air dryer is with 2 desiccant tower. The hot air from the oil free air compressor at 90°C -
180°C temperature ,is used to( TAD A)directly for regeneration of the desiccant. After
regeneration this air is cooled down to 30 -60°C and then it is dried in TAD B.

Desiccant - Activated Alumina (AL2O3 )

Volumetric flow rate - 70Nm3/min
Working pressure - 0.5-1.0MPa(g)
Dew point (ADP) - -40℃
Bulk density of desiccant - 720Kg/m3
Desiccant life - 5 Years
CYCLE TIME :
Adsorption time (per cycle) - 240 mins
Regeneration time (per cycle) - 200 mins
Heating time (per cycle) - 120 mins
Cooling time (per cycle) - 80 mins
COOLING WATER PARAMETERS
Pressure - 0.2-0.4MPa(g)
Flow - 30 m3/hour
Inlet temperature - 32℃ (Max 38℃)
Outlet temperature - 37℃ (Max 43℃)
AIR DRYER P&I DIAGRAM
Temperature Valves
PROCESS CYCLES :

1.Heating Process(A Adsorption B Heating)

2.Cooling Process (A Adsorption B Cooling)
3.PID Cooling Process (A Adsorption B PID Cooling)
4.Double Tower Adsorption (AB Simultaneous Adsorption)
5.Heating Process(B Adsorption A Heating)
6.Cooling Process (B Adsorption A Cooling)
7.PID Cooling Process (B Adsorption A PID Cooling)
8.Double Tower Adsorption (AB Simultaneous Adsorption)
1. Heating Process(A Adsorption B Heating)

High temperature compressed air passes

through auxiliary heater (or have), V10 valve
and V08 valve, enters Tower B to heat and
desorb the adsorbent in Tower B, passes
through V04 valve and V12 valve, enters No.2
cooler to cool down, passes through gas-liquid
separator to discharge liquid water, passes
through V01 valve to enter tower a for
adsorption, and then passes through v05 valve
to gas outlet.
2. Cooling Process (A Adsorption B Cooling)

After the high temperature compressed air is

cooled by No. 1 cooler, it passes through v09
valve and V04 valve, enters Tower B to cool
the adsorbent in Tower B from bottom to top,
passes through V08 valve and V11 valve,
enters No. 2 cooler.
To cool down, passes through the gas-liquid
separator to discharge the liquid water, passes
through V01 valve to enter tower a for
adsorption, passes through v05 valve to the
3.PID Cooling Process (A Adsorption B PID Cooling)

The high-temperature compressed air passes

through v09 valve and V12 valve after being
cooled by No. 1 cooler, enters into No. 2 cooler
for cooling, discharges liquid water through gas-
liquid separator, enters tower A and Tower B for
adsorption through V01 valve and V02 valve,
and then passes through v05 and v06 valves to
the outlet.V02 valve regulates the temperature of
adsorbent in Tower B by pulse cooling of gas
entering Tower B according to the change of
outlet temperature T5.
4.Double Tower Adsorption (AB Simultaneous Adsorption)

The high-temperature compressed air passes

through v09 valve and V12 valve after being
cooled by No. 1 cooler, enters into No. 2 cooler
for cooling, discharges liquid water through
gas-liquid separator, enters tower A and Tower
B for adsorption through V01 valve and V02
valve, and then passes through v05 and v06
valves to the outlet.
5.Heating Process(B Adsorption A Heating)

High temperature compressed air passes

through auxiliary heater (or have), V10 valve,
v07 valve, enters tower A to heat and desorb
the adsorbent in tower A ,passes through V03
valve, V12 valve, enters No.2 cooler to cool
down, passes through gas-liquid separator to
discharge liquid water, passes through V02
valve to enter Tower B for adsorption, and then
passes through v06 valve to gas outlet.
6.Cooling Process (B Adsorption A Cooling)

After the high temperature compressed air is

cooled by No. 1 cooler, it passes through v09
valve and V03 valve, enters tower A to cool the
adsorbent in tower a from bottom to top, passes
through v07 valve and V11 valve, enters No. 2
cooler to cool down, passes through gas-liquid
separator to discharge liquid water, passes
through V02 valve to enter Tower B for
adsorption, passes through v06 valve to outlet.
7.PID Cooling Process (B Adsorption A PID Cooling)
The high-temperature compressed air passes
through v09 valve and V12 valve after being
cooled by No. 1 cooler, enters into No. 2 cooler
for cooling, discharges liquid water through gas-
liquid separator, enters tower A and Tower B for
adsorption through V01 valve and V02 valve,
and then passes through v05 and v06 valves to
the outlet.V01 valve regulates the temperature of
adsorbent in tower a by pulse cooling of gas
entering tower a according to the change of
outlet temperature T5.
 8.Double Tower Adsorption (AB Simultaneous Adsorption)

The high-temperature compressed air passes

through v09 valve and V12 valve after being
cooled by No. 1 cooler, enters into No. 2 cooler
for cooling, discharges liquid water through gas-
liquid separator, enters tower A and Tower B for
adsorption through V01 valve and V02 valve,
and then passes through v05 and v06 valves to
the outlet.
HEATING PROCESS (A -ADSORPTION B- HEATING)
COOLING PROCESS (A -ADSORPTION B- COOLING)
PID COOLING PROCESS (A -ADSORPTION B- PID COOLING)
DOUBLE TOWER ADSORPTION (A&B SIMULTANEOUS ADSORPTION)
AIR RECEIVER TANK :
An air receiver tank is a closed vessel used to
provide temporary storage for compressed
air. Storing compressed air allows the system
to average the peaks in compressed air
demand over the course of a shift.
Design pressure - 1 Mpa
Operating pressure - 0.85Mpa
Design temperature - 100°C
Working temperature - 80°C
Quantity - 4 no’s
AIR RECEIVER TANK P&I DIAGRAM

Service Air Line

Instrument Air
Line
INSTRUMENT AIR CONSUME :

• Unit 1 & 2 BTG

• Auxiliary Boiler
• DM Plant
• Ammonia Storage Plant
• CW Pump House
• Hydrogen Generating Plant
• FGD
• Fuel Oil Tank Shutdown Valve
SERVICE AIR CONSUME :

• Unit 1 & 2 BTG

• Boiler light fuel oil supply

• FOPH
Thank You