UNIT 2-Instrument Air Supply System: Applied Instrumentation (4351701)
UNIT 2-Instrument Air Supply System: Applied Instrumentation (4351701)
UNIT 2-Instrument Air Supply System: Applied Instrumentation (4351701)
INTRODUCTION:
Instrument air systems must be as reliable as any other utility serving the plant
system. The quality of instrument air is so vital to modern process plants that it is
difficult to overemphasize its importance.
This becomes evident when one considers the small nozzles and passages through
which instrument air passes in the functioning of pneumatic control devices. Even
in plants that are primarily electronic, pneumatic power is still used for most of the
final control elements. Also, local control loops are still likely to be of the
pneumatic type.
The air used must be clean, dry and oil-free to ensure that small lines, restrictions
and nozzles will not be fouled or plugged by scales, dirt, oil or water.
Water in the lines can cause:
1. Corrosion and rusting of air systems and instrument devices
2. Scaling that may cause damage to delicate instrument devices and plug lines and
nozzles
3. Removal of lubricants from controllers
4. Blocked or ruptured instruments or air lines when freezing temperatures occur
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
in Table 9.1 should be helpful. The values given are in excess of the steady-state
air consumption requirements, but a large safety factor is needed in any case. Spare
capacity
It should be at least 10% for instrument additions and changes even when no
physical enlargement of the process is anticipated. If processes are to be enlarged
or added, spare capacity should be in proportion to the anticipated additions.
At least 10% extra capacity should be allowed for air dryer losses and leaks in the
distribution system. In deter- The preferred instrument' air system is one which is
separated from any other air system. Usually there are two mining compressor
requirements another 20% of the maximum system demand should be added to
avoid overloading the compressor.
Pressure level:-
The pressure levels used for instrument air systems vary from about 40 psig to as
high as 120 psig. The most common ranges are between 80 and 100 psig. The
increasing use of piston and cylinder operators for high torque requirements have
added to the need for higher pressure source levels. Seldom is the 40 psig pressure
level deemed sufficient in today's processing plant.
When a decision is reached on the pressure necessary in the main distribution
header, additional allowances need to be made for pressure drops in the drying and
accessory equipment. Ten to 15 psi should be allowed for the pressure drop for the
entire cleaning and drying system. This might consist of an after cooler, water
separator, pre- and after filters and air dryer.
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
Distinct systems used in a process plant: (a) an instrument air system and (b) a
plant air system furnishing air for operating and maintenance purposes such as for
cleaning uses and power requirements for pneumatic tools. Occasionally there is a
need for a third system to meet a process requirement.
Because plant air demand~ (and process also) are unpredictable, causing wide
variations in header pressure, the instrument air system is preferably an
independent system or is appropriately isolated from disturbances in the plant or
process air systems.
When air capacity requirements are small, self-contained systems such as shown in
Figure 1 may be used. It consists of an air-cooled compressor (plus spare), an air
receiver (complete with cooling, lubricating. regulating and starting system
integrally mounted on the compressor), an after cooler, filters and dryer. Instead of
the spare or standby compressor, a tie-in might be made to a plant air system for
makeup.
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
CLASSIFICATION OF COMPRESSOR
Reciprocating Compressors
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
After discharging high pressure gas, piston or rotor moves to its new
position for suction of new volume of gas. The cycle repeats for the
continuous compression of the gas.
Rotary Compressors
Compressor controls
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
l. The inlet valves may be held open during both the suction and
compression strokes-thus no air will be compressed in the cylinder. 2.
Clearance pockets may be used which are automatically controlled by the
pilot, reducing the volume of compressed air delivery. 3. On rotary
compressors, a valve, which completely closes the intake line, prevents the
intake of air. 4. On some compressors, the speed is varied in response to
pressure changes on the pilot. As the volume of output air varies directly
with the compressor speed, the output follows the demand. This is a
common method with reciprocating steam driven engines or gasoline and
diesel engines. 5. On small compressors, a type of control known as
"automatic start and stop," which responds to a pressure actuated switch,
opens or closes the motor circuit as demand varies. Large compressors are
usually kept running when unloaded
Dryer
Water, the most serious contaminant in compressed air systems, causes rust
and corrosion of piping and fittings and carries dust, dirt and other solids to
instrument orifices and other restrictions resulting in the plugging of these
devices. Pipe capacity is reduced by water, and when ambient temperatures
drop, ice formations may plug or burst the lines. All atmospheric air contains
some water vapour. During the compression process, as the air pressure
increases, a corresponding increase in air temperature occurs due to the work
of compression. Even though the decrease in volume of a given quantity or
air could result in the precipitation of water, this does not occur due to the
high air temperature. Therefore, the compressor discharge air contains the
same quantity of moisture as the compressor inlet air. When an air-vapour
mixture is cooled at constant pressure, the temperature at which the vapour
becomes saturated and moisture begins to condense is called the "dew point"
temperature of the air. As the air passes through the after cooler, its
temperature rapidly drops to a point below the dew point, resulting in
condensation of from 70 to 90% of its water content. The use of after coolers
is essential to reduce the load on dryers. If the air temperature is
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
subsequently increased, the dew point will remain at the lowest temperature
to which the air was previously subjected, provided that the condensed water
has been trapped out. Otherwise, the condensate will vaporize again and
raise the dew point. A dew point of -40°F at line pressure is commonly
accepted as a standard for instrument air systems since temperatures
generally do not drop below this value. In areas of extreme cold the dew
point· may be as low as -100°F. The dew point should be several degrees
below the lowest temperature the air will encounter in the system For indoor
installations or where air lines are never exposed to low temperatures, a -
40°F dew point is not necessary. In determining the minimum temperature,
the cooling effect of adiabatic expansion of the compressed gas to lower
pressures must be considered. The reater the gas expands in volume, the
lower the temperature drops. Expansion cooling effects should be considered
in specifying the dew point requirement. The two basic types of dryers used
for instrument air systems are the refrigeration and the dessicant. Mechanical
separators are available (expansion and cyclone types), but they do not
produce the quality of air required for instrument air use. The selection of a
particular type depends on required dew point, quantity of air flow, air
pressure, desired relative humidity and system operating costs (electricity,
steam, water, etc.).
Types of dryer
1. Refrigerated
Refrigerated Dryer
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
1.compressor
2 condenser
3 metering device
4 heat exchanger
5 air coil
6. Trap
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
Compressor:
It is also used to pump the Freon gas throught the system.the condition of
Freon gas is vapour state.
Condenser:
Super heated Freon gas from compressor enter into the condenser
The main function of condenser is to cool the Freon gas. condenser can be
air cooled or water cooled. In air cooled condenser exhaust fan is mounted
above the condenser. exhaust fan will remove heat from condenser by
exhausting hot air outside.
Heat exchanger:
The low temperature Freon gas from metering device passes through the
heat exchanger. Freon gas is directly exposed to air coil where air supply is
taking place.
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
Condensed moisture collected in the trap &gets drain After heat exchanging
Freon gas will return back to compressor.
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
So now that we know why we need dry compressed air, let’s talk about how
desiccant dryers create it.
Pre-filtration
Compressed air contains contaminants that can adhere to the surface of desiccant
beads (often referred to simply as desiccant). This decreases the efficiency of the
desiccant by reducing the amount of moisture it can adsorb over time.
Pre-filtration minimizes contamination of the desiccant by removing particulates
from the air stream before the air reaches the desiccant bed. Reduced
contamination can extend the life of the desiccant beads, which can reduce
operating costs by requiring them to be replaced less often.
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
Desiccant dryers manage the process of drying air and regenerating desiccant by
using paired towers, coordinating adsorption and desorption between the two
towers (A and B) by cycling through a series of stages.
Stage 1
Drying: Tower A’s inlet valve opens and it starts receiving saturated compressed
air. As this wet air flows through tower A, the desiccant beads adsorb water vapor,
drying the air stream. This dry compressed air stream exits tower A and flows
downstream. In heatless and externally heated dryers, a small portion of this dry air
(“purge air”) is redirected towards tower B for use in regeneration.
Regeneration: At the same time, the exhaust valve of tower B opens and either
atmospheric air (heated blower purge dryers) or purge air rapidly lowered to
atmospheric pressure (heatless and externally heated dryers) flows across tower
B’s desiccant. In externally heated and heated blower purge dryers, the air
temperature is also raised, increasing the air’s moisture capacity. As this lower
pressure and possibly heated dry air flows through tower B, the desiccant releases
its moisture into the air stream, which exits tower B into the atmosphere.
Stage 2
Tower B’s exhaust valve is closed and the tower is re-pressurized. Once the
pressure reaches the compressed air stream’s pressure, tower B is ready to start the
drying process.
Stage 3
Drying: Tower B’s inlet valve opens and it starts receiving saturated compressed
air. As this wet air flows through tower B, the desiccant beads adsorb water vapor,
drying the air stream. This dry compressed air stream exits tower B and flows
downstream. In heatless and externally heated dryers, a small portion of this dry air
(“purge air”) is redirected towards tower A for use in regeneration.
Regeneration: At the same time, the exhaust valve of tower A opens and either
atmospheric air (heated blower purge dryers) or purge air rapidly lowered to
atmospheric pressure (heatless and externally heated dryers) flows across tower
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
A’s desiccant. In externally heated and heated blower purge dryers, the air
temperature is also raised, increasing the air’s moisture capacity. As this lower
pressure and possibly heated dry air flows through tower A, the desiccant releases
its moisture into the air stream, which exits tower A into the atmosphere.
Stage 4
Tower A’s exhaust valve is closed and the tower is re-pressurized. Once the
pressure reaches the compressed air stream’s pressure, tower A is ready to start the
drying process.
Post-filtration
Some types of desiccant can shed small particles, either due to saturation or
pressure swings, a phenomenon known as “desiccant dusting.” To prevent this
“dust” from contaminating downstream tools, products, and processes, the
compressed air stream is filtered again after it leaves the desiccant bed.
Types of desiccant
The type of desiccant used can affect many aspects of dryer performance, in
particular the dew point of the dryer. The most common desiccants used and their
dew points are:
Silica gel: −40°F (−40°C) dew point
Activated alumina: −40°F (−40°C) dew point
Molecular sieve: −100°F (−73°C) dew point
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
Electronics fabrication
Robotic machinery
Oil and gas
Because moisture does not condense in a desiccant dryer, they are also frequently
used for any applications that have ambient conditions not suitable for other types
of dryers, for example in outdoor environments that reach sub-freezing
temperatures.
Heated and heatless desiccant air dryers are two common types of equipment used
to remove moisture from compressed air systems. They work on different
principles and have distinct advantages and applications. Here are the key
differences between heated and heatless desiccant air dryers:
1. Operating Principle:
Heated desiccant air dryers use heat to regenerate the desiccant material (usually
a type of silica gel or alumina) after it has absorbed moisture from the compressed
air.
In these dryers, a portion of the dried compressed air is diverted and heated to a
high temperature. This heated air is then used to regenerate the desiccant bed by
driving the moisture out of it.
Heated air is typically used in a "purge" cycle to remove moisture from the
desiccant material.
2. Energy Consumption:
Heated desiccant dryers typically consume more energy because they require
external heating elements to regenerate the desiccant material.
They are more efficient in terms of regeneration, but the energy cost can be higher.
3. Applications:
AVPTI,RAJKOT P.R.THUMAR
Applied instrumentation(4351701)
Heated desiccant dryers are often used in applications where extremely low dew
points (very dry air) are required, such as in pharmaceutical, electronics
manufacturing, and critical instrument air systems.
Heated dryers are generally more complex due to the inclusion of heating elements
and associated controls.
o They may require more maintenance and have higher initial costs.
AVPTI,RAJKOT P.R.THUMAR