UNIT 2-Instrument Air Supply System: Applied Instrumentation (4351701)

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Applied instrumentation(4351701)

UNIT 2-Instrument Air supply system

 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

In view of the continued importance of dependable, high quality instrument air


systems, a review is presented of some of the factors that should be considered in
designing instrument air systems. These factors include:

 Sizing criteria for air supply system:-


The capacity requirement of an instrument air system is determined by listing all
the consumers which are to operate simultaneously. This is not an easy task, for
there is no way of knowing exactly how many instruments will be operating at a
given time. Many instruments are of a constant bleed type--,-there is a constant use
of some air regardless of the state of the measurement or control function of the
instrument. More air is used when upsets or wide variations in measurement or
control occur than under stable process conditions. Some rules-of-thumb are used,
however, to help overcome the lack of knowledge of actual conditions. .
A listing is given in Table of several air users and their rule-of-thumb capacity
requirements. When manufacturer's data are available on the consumption of these
users, that data should be used. However, in the absence of reliable data, the values

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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.

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 Supply system for low air requirement

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.

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 Supply system for Large air requirement

The major parts of an instrument air supply system are:


 The Electric motor
 The Compressor
 The Inlet Air Filter
 The After Cooler
 The Moisture Separator
 The Condensate Trap
 The Air Receiver
 The Safety Relief Valve
 The Pressure Gauge
 The Oil Remover
 The Dryers
 The Air Distribution System

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 The Electric Motor


 The primary function of the electric motor is to provide a rotary motion to
drive the compressor.
 The Compressor
 The Compressor converts the mechanical energy provided by a prime mover
(e.g. an electric motor) into the potential energy of compressed air.
 The Inlet Air Filter
 This removes dust and dirt from atmospheric air before it enters the suction
inlet of the compressor.
 The After Cooler
 This cools the air leaving the air compressor. This is done by passing
cooling water over the after cooler chamber.
 Moisture Separator
 This removes most of the moisture from the air.
 Condensate Trap
 This collects the condensed liquid from the moisture separator and drains the
liquid periodically when the Condensate levels gets too high.
 Air Receiver
 This stores large volumes of the compressed air. It also provides an
emergency supply of air for a short period of time in the event of compressor
failure.
 Safety Relief Valve
 A Safety Relief Valve is used to discharge excess pressure automatically
if maximum pressure develops in the air receiver.
 Pressure Gauge
 This indicates system output pressure.
 Oil Remover
 This is used to remove oil carried out by the air during the compression
cycle. If the oil vapour is not removed from the compressed air it slowly
forms into droplets large enough to plug up tiny instrument tubings and
nozzles.
 Dryers
 These dry any moisture that is left in the air.

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 Air Distribution System.


 This is the final step in producing a properly balanced instrument air
system. It should provide delivery to all air users with a minimum supply
variation of approximately 125 to 150 psi or 8.618 to 10.342 bar of pressure.

 CLASSIFICATION OF COMPRESSOR

Positive Displacement Compressor Types

Positive displacement compressors are available in two main types: reciprocating


compressors and rotary compressors. The choice of compressor type depends on
several factors, such as the required flow rate, pressure, and gas composition.
Reciprocating compressors are typically more suited for high-pressure
applications, while rotary compressors are better suited for high-flow-rate
applications.

Reciprocating Compressors

Reciprocating compressors use a piston and cylinder to compress the gas.


The piston moves back and forth in the cylinder, drawing in gas on the
downstroke and compressing it on the upstroke. This process creates a cyclic

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compression of the gas in the chamber, delivering a constant flow of


compressed gas to the outlet.

Positive displacement compressors are mechanical devices used to increase the


pressure of a gas by reducing its volume. The major advantage of positive
displacement compressors is that they deliver a constant flow of gas at a high
pressure. In this post working principle of positive displacement compressors has
been discussed along with its types, advantages and disadvantages

 The compressor chamber is empty initially. The volume of compression


chamber is slightly larger than the amount of gas to compressed.
 When the compressor starts, the piston or rotor inside the chamber starts
moving. This reduces the volume of the compression chamber.
 As the volume of the chamber decreases, gas inside compression chamber
forced to compress and results in increase of pressure.
 Once the pressure of the gas inside the chamber reaches the predetermined
level, gas is discharged through a outlet discharge valve.

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 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

Rotary compressors use a rotating element, such as a screw, vane or lobe to


compress the gas. As the element rotates, it traps gas and moves it towards the
outlet, where it is compressed and discharged. Rotary compressors are available in
several configurations, including helical screw compressors, scroll compressors,
sliding vane compressors, liquid ring compressors and lobe compressors

 Compressor controls

Since compressed air' is generally required in varying quantities at a


relatively constant pressure, compressor regulators or controls are used to
vary the delivery of the compressor. If the pressure rises too high, the pilot
(a pressure responsive device) operates to reduce the air delivery; if the
pressure falls too low, the pilot operates to increase the air delivery. Several
mechanisms are used as unloading devices to vary the delivery of
compressed air

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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

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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

2. Desiccant (heated and heat less)

 Refrigerated Dryer

Refrigerated air dryer works on the principle of refrigeration.

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Equipments in Air dryer

1.compressor

2 condenser

3 metering device

4 heat exchanger

5 air coil

6. Trap

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Compressor:

It is used to increase the pressure & temperature of the Freon gas.

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.

The condition of Freon gas is liquid state.

Expansion or metering device:

Freon gas from condenser passes through metering device.i.e capillary


tube.in this Freon gas temperature & pressure will reduce further. The
condition of Freon gas is liquid.

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.

By this air gets cool to very low temperature.upon reaching to temperature at


4degree C moisture in air stats condensing.

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Condensed moisture collected in the trap &gets drain After heat exchanging
Freon gas will return back to compressor.

 Heated and heatless dryer

A- four-way inlet switching valve


B- desiccant bed
C- filter
D- outlet check valve
E- purge throttling valve
F- purge indicator
G- purge flow orifice
H- valve
I- heater tube
J- electric heater
K- plenum area of the chamber
L- purge exhaust valve

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A typical flow circuit is shown in Figure .


Wet air enters the four-way inlet switching valve (A), passes through the left
desiccant bed (B), through the stainless steel cleanable outlet filter (C) and outlet
check valve (D) to the dry air outlet.
A small portion of dried air passes through the purge throttling valve (E), purge
indicator (F) and purge flow orifice (G) which controls the flow rate. Metered
purge then passes through the right purge flow check valve (H) through the heater
tube (I) and over the electric heater (J). Heated purge then enters the plenum area
of the chamber (K) where it is dispersed downward through the wet desiccant bed
in. a direction counter current to the drying flow.
The purge an, now carrying previously adsorbed moisture, exits to atmosphere
through the four-way and purge exhaust valve (L).

Why do compressed air systems need dry air?


Your compressed air system could need dry compressed air for a number of
reasons:

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 The end process or product is moisture-sensitive. Some applications, like


the powder coating process mentioned above, or pharmaceutical, food, and
electronics products and even packaging, are particularly sensitive to excess
water vapor in the compressed air stream. Failure to dry the air sufficiently
could result in a botched process or unusable product.
 The application is moisture-sensitive. Even when no end product is being
produced, tools and instruments used in many applications, for example
instrument air, often require air to be dried to a certain level (known as the
dew point) to work well, or even to work at all.
 To maintain the integrity of your compressed air system. Regardless of
your end product, process, or application, dry air can benefit all compressed
air systems by minimizing the risk of rust, mold, or other contaminants in
your compressed air system. Once rust or mold are in the system, repairing
or cleaning the system can be costly.

So now that we know why we need dry compressed air, let’s talk about how
desiccant dryers create it.

How does a desiccant dryer work?


The short answer is that desiccant dryers remove moisture from the compressed air
stream chemically using a process called adsorption.

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.

The desiccant drying process (adsorption and desorption)


In order to continuously provide dry air downstream, a desiccant dryer needs to:
 Collect moisture from the compressed air stream onto the desiccant
(adsorption).
 Release moisture from the desiccant beads to the outside air (desorption).
o This part of the process is called regeneration, and the reason
desiccant dryers are sometimes called regenerative dryers.

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o Three commonly used processes for regenerating desiccant that will


be covered below are:
 Heatless
 Externally heated
 Heated blower purge

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

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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.

Continuous drying cycle


The four stages above make up one drying cycle. When a drying cycle ends the
next starts automatically as long as the desiccant dryer is running.

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

Applications of desiccant dryers


Desiccant dryers are most commonly used when a process needs very dry air (i.e.
air with a very low dew point), including but not limited to:
 Food and beverage
 Pharmaceuticals
 Laboratories
 Healthcare facilities
 Coating and painting processes
 Outdoor HVAC controls

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 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:

 Heated Desiccant Air Dryer:

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:

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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.

They are suitable for applications with high moisture loads.

4. Complexity and Maintenance:

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.

 Heatless Desiccant Air Dryer:


 Heatless desiccant air dryers do not use external heat sources for
regeneration. Instead, they rely on a fraction of the dried compressed air
itself to regenerate the desiccant material.
 In these dryers, two desiccant beds are used, with one bed in the drying
phase while the other is in the regeneration phase. The dry, compressed air
flows through one bed, while the other bed is depressurized and allowed to
release the absorbed moisture, often through a depressurization and purging
process.
 Heatless dryers do not use external heat sources, which can result in lower
energy consumption.
 However, they are less energy-efficient in terms of desiccant regeneration
compared to heated dryers.
 Heatless desiccant dryers are commonly used in general industrial
applications where moderately dry compressed air is sufficient, such as for
pneumatic tools, painting, and automotive applications.
 They may be more cost-effective in applications with lower moisture loads.
 Heatless dryers are simpler in design and may have lower maintenance
requirements.
 They are often more cost-effective for smaller-scale applications.

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