Utilities - Instrument Air

September 18, 2002

Introduction Associated Links

Air Quality 
        Dew Point
        Oil Content
        Particulate
        Temperature
Control Philosophy
Compressor
Inlet Air Filters
After Coolers
Air Receiver
Oil Filters
Air Dryers
        Heatless Regenerative Desiccant Dryers
        Heat Regenerative Desiccant Dryers
        Refrigerated Dryers
After Filters

Introduction

The instrument air system supplies dry and oil free air to the instrument air system of the sulphuric acid
plant.  A typical instrument air system consist of the following components:

 Compressor
 Oil Filter
 Particulate
 Air Receiver
 Air Dryer
 Local Control Panels

The quality of instrument air is what distinguishes it from a compressed or service air system.

Air Quality 

The quality of the air is important to ensure that instrumentation will function properly and reliably.   The
most important parameters in specifying air quality are:

 Dew Point
 Oil Content
 Particulate
 Temperature

The Instrument Society of America sets quality standards for instrument air in ISA S7.3.

Dew Point
The dew point temperature or saturation temperature can be defined as the temperature at which
condensation or moisture begins when moist air is cooled.  This temperature can be determined by
observing, either visually or by a photoelectric cell, condensation of water vapour on a polished metal
surface that is slowly being chilled.  Indirect methods for measuring moisture include wet and dry bulb
psychometry, adiabatic expansion, electrical resistivity and methods that depend on the hygroscopic
properties of various materials. 

When an air-water vapour mixture is compressed: 

          1. its ability to hold water is decreased;

          2. water vapour will start to condense at a higher temperature; and

          3. the dew point of the mixture at elevated pressure will be higher than that of the same
mixture at atmospheric pressure.

The dew point required for an instrument air system is generally set by the minimum ambient temperature
to which the instrument air system will be exposed.  The dew point at line pressure shall be at least 10°C
(18°F) below the minimum local recorded ambient temperature.

In cold climates, a -40°C dew point is typically used.  In warmer climates the dew point temperature can
be increased appropriately.

Under no circumstances should the dew point at line pressure exceed 2°C (35°F).

In is important that the dew point temperature be specified at the operating pressure of the instrument air
system and not atmospheric pressure.  This will ensure that no condensation of water will occur anywhere
in the system.

Oil Content

Oil free air is generally required for an instrument air system.  In an oil free system, an oil content of less
than 0.01 ppm is generally specified.

Where a instrument air consumer requires air with oil for lubrication purposes, individual oilers are
installed specifically for the consumer.

Particulate

Particulate in the air may plug the small passages in some valves and instruments.  Instrument air is
generally filtered to remove particulate matter to a level less than 0.02 mg/m³ (size 100% < 0.01 micron). 

Temperature

When any gas is compressed its temperature will increase.  For and instrument air system this increase in
temperature is undesirable.  After coolers are generally provided immediately after the compressor to cool
the air and remove the heat of compression.  A typical outlet temperature is a maximum of 40°C.

Control Philosophy
In some systems, two compressors are provided to ensure greater reliability and availability.  One
compressor unit is designated the operating unit while the other is placed on automatic standby.  If the
operating unit should fail, the standby unit comes on line to ensure uninterrupted supply of instrument air. 

A typical means of controlling when a compressor load/unloads is as follows::

                                        Duty                  Standby

                                    Compressor       Compressor
 
High/High Pressure            Unloads                   -
High Pressure                         -                    Unloads
Low Pressure                      Loads                    -
Low/Low Pressure                   -                     Loads 
 

Compressor

Air compressors generally come as an integrated unit consisting of the following components:

a)      Compressor
b)      Inlet air filter
c)      Drive motor
d)      Lubrication system
e)      Oil separator
f)        After coolers
g)      Control system and panel
 

All components are housed in an enclosure to minimize noise.

Compressors must be sized to deliver the maximum quantity of air at the specified pressure.  Various
types of compressors are available, including:

 Reciprocating oiled piston

 Reciprocating oiless piston
 Rotary vane
 Rotary liquid ring
 Diaphragm
 Rotary Screw
 Centrifugal

Compressors of the non-lubricated type are commonly used to prevent problems with oil or lubricant
contamination of the air.  Where lubricated compressors are used, provision must be made to adequately
remove these contaminants from the air.

Inlet Air Filters

Generally, the instrument air system intake should be located outside and in the coolest area.  The lower
the air intake temperature, the greater the compressor efficiency.  If contamination exists in the
compressor intake area, the air should be taken from an elevated or remote location free from
contamination.
Inlet air filters are essential to remove grit and dust that are present in practically all plants.   Removal of
these substances is important in order to achieve the desired air quality and to protect the compressor,
since any solids in the air will cause wear on the moving parts.  These filters must be regularly inspected
and replaced.

After Coolers

The compression of air results in a rise in the temperature of the air.   After the compressor the air is
passed through an after cooler to reduce its temperature.  Upon cooling the air temperature may be below
its dew point, so a mechanical moisture separator is provided.

After coolers are generally water or air cooled.  Water-cooled after coolers are generally sized to achieve
a 5.5°C to 8.5°C (10°F to 15°F) approach to the cooling water supply temperature.   Air-cooled after
coolers are generally sized to achieve a 14°C to 17°C (25°F to 30°F) approach to the ambient air
temperature.

Air Receiver

The air receiver is sized to store enough air to handle system demand surges, to allow time for moisture
separation and to provide a reserve for orderly or emergency shutdown.  The receiver pressure is usually
used for loading and unloading the compressor.  A receiver that is too small will result in a compressor
that is constantly loaded which will shorten the life of the equipment.

The receiver ambient temperature is typically lower that the dew point of the air entering the receiver.  
This causes moisture to condense inside the receiver.   An automatic liquid drain
device must always be furnished on an air receiver to dispose of any moisture.

Oil Filters

Oil and lubricants are major contaminants in instrument air systems.   They enter the
air stream in liquid, aerosol (mist) and vapour form.  Oil and lubricants are most
troublesome when they combine with moisture and solid contaminants to form a
sludge that can clog instruments.  Oil can also contaminate desiccants in air dryers.

Oil filters are generally installed after the air receiver and before the air dryers.   These
filters will generally be installed in a duplex fashion allowing one filter to be maintained
while the other is in operation.

Air Dryers

Water in an instrument air system can cause rust in distribution pipes or freeze in
exposed outdoor lines.  It is important to dry the air prior to distribution to prevent
problems in the system.

Air drying is generally done in one of two ways:

a)   Heatless Regenerative Desiccant Dryers

b)   Heat Regenerative Desiccant Dryers

 c)   Refrigerated Dryers

Heatless Regenerative Desiccant Dryers

Heatless regenerative dryers utilize the principle that expansion of

a compressed gas from a high pressure to a low pressure reduces
the partial pressure of all constituents in a proportion equal to the
ratio of absolute pressure change.  Thus, a water saturated
adsorbent will give up its water vapour to a lower vapour pressure
environment.  In practice this is achieved by taking a portion of the
high pressure dry air and expanding it to essentially atmospheric
pressure and passing it through the desiccant bed to strip off the
water content.

The disadvantage of heatless type regenerative desiccant dryers is

the loss of a portion of dry air used to regenerated the desiccant
bed.

The heatless dryer works by passing compressed air through a

tower filled with desiccant.  Moisture from the air stream is
adsorbed onto the desiccant thereby producing dry outlet air. 
While one tower is on line performing the drying function, the
second tower is off line being regenerated by a portion
(approximately 10 to 20%) of the dry discharge air.

This operation is controlled by valves (V1 and V2) which divert the flow of air to the on-line tower and
away from the regenerating tower.  At the same time, a purge valve (V3 or V4) allows the regenerating air
flow entering the off-line tower to escape and thereby purge the moisture
adsorbed from the desiccant to the atmosphere.

Once the regeneration process is complete the off-line tower is re-pressurized to

prevent fluidization of the desiccant bed.  The purge valve (V3 or V4) will close
so that the off-line tower is allowed to re-pressurize.

After re-pressurization is complete, the flow valves (V1 and V2) will divert the
drying air flow to the previously off-line tower.  Simultaneously, a purge valve (V3
or V4) will open allowing the previously on-line tower to de-pressurize and begin
regeneration.  The sequence is repeated continuously ensuring a constant
supply of dry air to the system.

Heat Regenerative Dryers

Heat regenerative dryers utilize the principle that a hot gas can hold a larger
amount of water vapour than a gas at a lower temperature.  Thus, a water
saturated adsorbent will give up its water to a gas at a higher temperature.  Hot
air, heated by an electric or steam heater passes through the desiccant bed
removing the water from the adsorbent and regenerating the bed.
Refrigerated Dryers

Refrigeration type dryers utilize the principle that the lower the dry bulb temperature of the air, the lower
the water vapour content.  Typical, refrigeration type dryers are capable of achieving a dew point
temperature of -1.7°C.

After Filters

The after filter provides final cleaning of the compressed air stream by removing particulate matter from
the dryer discharge.  After filters are required on all instrument air systems, particularly desiccant-type
dryers to prevent desiccant dust from passing downstream.  These filters will generally be installed in a
duplex fashion allowing one filter to be maintained while the other is in operation.