Instrument Air Compressors and Drives

Air compressors shall be designed for continuous operation with high efficiency
to satisfy the system requirements. Satisfactory operation in parallel shall be
ensured without any uneven load sharing, undue vibration, noise etc.
The design shall incorporate every reasonable precaution for the safety of all
operation and maintenance personnel. Each compressor unit should have all
moving parts protected by a guard.
The scope of supply shall include all the necessary compressed air plant
complete with compressor coolers, necessary isolating and non-return valves,
pressure relief valve, water separators, silencers and vent pipe work, which
shall be ducted to a safe discharge outlet.
4100% (2 working + 2 standby) capacity instrument air compressors shall be
provided for both units.
The output from each set of working compressors (as applicable), expressed as
free air delivered (FAD) at ambient condition, shall be sufficient to meet the
instrument air requirement for one unit and silo area air requirement such as
silo bag filter cleaning valve actuation, etc. At least 10% margin shall be
provided on compressor capacity over and above the maximum flow
requirement. The bidder shall furnish detailed calculations of compressor
sizing with the bid. A discharge pressure of 8 kg/cm2 with three steps of
unloading and design ambient of 50 degree C ambient air temp and 100% RH
shall be considered for sizing of the compressors.
Compressors shall be of reciprocating oil free type. All instrument air
compressors and their drives provided under this contract shall be completely
interchangeable.
The wall thickness of the cylinders shall be sufficient to withstand the maximum
cylinder pressure and to permit successive re-boring without hazard.

Piston shall be provided with piston rings to seal the leakage of compressed air.
The piston rings shall be self-lubricating material preferable graphite
impregnated Teflon. In case the cylinder is horizontal, suitable slipper rings
shall be provided to avoid rapid wear and/or distortion of the piston ring.
Each compressor shall have an inlet filter (dry type) unit to protect the
compressor. The filter inlet area should be large enough to ensure frequent
filter changes are not required.
A crank shaft driven positive displacement lubricating pump shall be used for
lubricating the bearings and any other parts needing lubrication.
Cooling water requirement, if any, shall be arranged by the bidder.
Bidder shall include an inlet and/or outlet silencer so that each compressor unit
complies with the noise requirements.

2.8.18.1

Air Receivers
Each compressor shall be provided with an air receiver of ample size of so that
delivered air pressure is kept within 5% of rated pressure without excessive
start/stop operation in the working cycle.
Air receivers shall be located convenient to compressor discharge. The receivers
and associated fittings shall comply with BS:5169 and BS:1123 or other
approved standards.
The receivers shall each be supplied complete with test certificate, safety relief
valve, fusible plug, pressure gauge, flanged inlet and outlet connections,
inspection manhole (in accordance with Clause 25.2.4 of BS:5169-1975, or
similar international equivalent), screwed drain connection, automatic drain trap
with balance line, drain trap isolating valve, balance line isolating valve and
manual drain valve, nameplate, support frame or legs, and a set of suitable
foundation bolts.
As far as possible the design, manufacture and performance of air receivers shall
be in accordance with the following latest applicable standards :

2.8.18.2

1)

IS : 2825 Code for unfired pressure vessels.

2)

ASME-Sec. VIII Div.-1 Code for unfired pressure vessels.

3)

BS : 487 Fusion welded steel air receivers.

4)

IS : 7936 Air receivers for compressed air installations.

Water Separators
The Bidder shall supply water separators complete with automatic drain traps.
Each separator shall be rated for twice the individual compressor flow at 1 bar
above maximum operation pressure. Each water separator shall have flanged
connections.

2.8.18.3

Air Drying Plant

One no. each for each compressor Air drying plant shall receive compressed air
saturated with moisture. They shall be capable of operating continuously to
provide reliable, moisture free compressed air supply. Dew point of the outlet
air measured at the operating pressure shall be as mentioned in the data sheet or
lower throughout the working of the drying plant.
The adsorber tower shall be sized for a drying cycle (i.e. the time any particular
tower is adsorbing) of period as specified (8 hours). After this period the
adsorber tower will be put under reactivation operation while the other will take
over the duty.
The above stated change-over from drying duty to reactivation or vice-versa shall
be fully automatic with manual over ride facility.
The four-way valves shall not be used in the air drying plant piping circuit for
changeover facilities.

Air drying plant shall be complete with all pipings, valves, instruments and other
accessories as required for safe and satisfactory operation and reactivation of
the plant. Open through system shall be used for reactivation.
Atmospheric air is filtered and is passed through the wet desiccant by a blower
with the help of proper valve arrangements after heating it to required
temperature by an electric heater. This moist air is exhausted to the
atmosphere. Suitable solenoid and pressure reducing valves for slow
depressurisation and re-pressurisation of the adsorber tower shall be provided
for such case.
The filtering media for prefilter shall be cable/candle type ceramic filter
designed to withstand at least 50% of the static pressure applied as
differential pressure. Pre-filter shall be provided with isolation valves.
Quantity of desiccant shall be calculated giving the consideration to the residual
moisture content at the end of regeneration cycle. Bidder shall submit detailed
calculations in support of material and quantity of desiccant offered alongwith
curves (with ref. to the source of these curves) indicating variation of
adsorption capacities with temp. at various R.H. at working pressure of 8
kg/cm2(g). Bidder shall also indicate the residual moisture left in the desiccant
after regeneration. For calculating the desiccant quantity, adsorption capacity
and density to be considered shall not exceed 10% and 550 kg/m3 respectively.
Dew point of outlet air shall be considered as (-) 40 degree C at 1 ata pressure.
Desiccant beds shall be designed with sufficient cross-sectional area for air flow
resulting in low air velocity and consequently low pressure drop.
The adsorbent material shall be supported at top and bottom by stainless steel
(AISI 304) 40 mesh strainer, on mild steel plates.
Adequate free board (minimum 20% of desiccant bed depth) shall be provided to
dislodge the entrained particles from the adsorber.
The adsorber tower shall be provided with suitable inspection window made of
glass/pespex for observation of the adsorbent conditions and desiccant filling
and removal connection.
Each air drying plant shall be completed with suitable after filters in the down
stream of the adsorber towers. After filters shall be provided with individual
isolating valves, 100% standby or bypass valves. After filter shall prevent any
carry-over of desiccant particles with the effluent air stream.
For reactivation air drying plant shall be provided with the air blowers and drive
of sufficient capacity and pressure for supplying air.
Dry type air filter at the suction of blower shall be provided.
Heater shall be used to heat the air upto the required temp. for the purpose of
reactivation of wet desiccant bed. Suitable temp. and pressure indication shall
be provided at the outlet of the heater shell. The heater shall be fabricated as
per IS:2825 or approved equal. The heater shall be thermostatically controlled,
electric type and shall preferably of flanged type so that replacement burnt out
heating element or other maintenance work is easy.

All pressure vessels such as moisture separator, prefilter and after filter casings,
adsorber towers etc. shall be designed as per IS:2825 or approved equal. All
vessels shall be Class-II type as per the said standard. Adequate provisions for
manhole/handhole, relief valve, draining trap station shall be made. Internal
surfaces of all the vessels shall be suitably protected against corrosion and
rusting.
Material of construction shall be as follows:
Compressor

To suit service condition and as per relevant

codes/standards

Air receiver

IS:226/IS:2002/IS:2062

Inter Cooler and After

Cooler
Tube

S.S.

Shell

SA 285 Gr. C

Air drying plant

Retention mesh for Silica SS
Gel
and
other
components coming in
contact with moisture.
2.8.18.4

Drive Motor
Drive motor shall be connected to the air compressors directly or through any
suitable type of power transmission system.
The continuous motor rating (at 50C) shall be at least fifteen per cent (15%)
above the maximum load demand of the compressor in the entire operating
range to take care of the system frequency variation. Total maximum load
demand shall include air compression power plus any power consumed in
auxiliaries like cooling fan etc. When the driver is not directly coupled to the
compressor, due account shall be made for losses in power transmission in
addition to the above 10% extra margin.

2.8.18.5

Instruments
Each Compressor shall be provided with the following instruments as a
minimum:
(i)

Pressure Gauges

a)

with each air receiver for air pressure

1 No.

b)

after each stage (LP & HP) for air pressure

1 No.

c)

at the lubricating oil inlet for oil pressure

1 No.

d)

e)

f)

g)

h)

j)
k)

at the prefilter (air drying plant) inlet and

outlet for air pressure
at the adsorber tower inlet & outlet for
air pressure

: 1 No. each

: 1 No. each

at the after-filter (air drying plant)

outlet for air pressure

1 No.

at the blower (air drying plant) outlet

for air pressure

1 No.

with the air receivers on instrument

air line near each unit for air pressure
at the cooling water inlet to each
compressor unit for C.W. pressure
at the instrument air ring header
for air pressure

l)

at the inter-cooler outlet for C.W. pressure

m)

before air receiver for each compressor

for C.W. pressure

1 No.

1 No.

1 No.
:

1 No.

1 No.

n)

at the after-cooler inlet for C.W. pressure

(ii)

Temperature Gauges

a)

after each stage (LP & HP) for

air temperature

: 1 No. each

at the C.W. outlet of each cylinder

for C.W. temperature

1 No.

at the inlet of HP cylinder for

C.W. temperature

1 No.

at the after-cooler outlet for

C.W. temperature

1 No.

at the after-cooler outlet for air

temperature

1 No.

b)

c)

d)

e)

f)

with each air receiver for air temperature

g)

at the adsorber tower inlet & outlet

for air temperature

1 No.

at the outlet of heater for air drying

plant for air temperature

1 No.

h)

i)

at the lubricating oil inlet for

1 No.

1 No.

oil temperature
j)

k)

at the lubricating oil in crank case

for oil temperature

Pressure Switches

a)

with each air receivers

1 No.

1 No.

i)

for air pressure high

1 No.

ii)

for air pressure low

1 No.

iii)

for load/unload

: 1No. each

iv)

for start/stop

: 1 No. each

b)

at the lubricating oil inlet for oil pressure low

c)

at the compressor discharge

-

e)

1 No.

at the cooling water inlet to each

compressor unit for C.W. temperature

(iii)

d)

1 No.

for air pressure high

for air pressure low

:
:

1 No.
1 No.

at the air drying after filter outlet for

instrument air pressure low

1 No.

at the instrument air ring header

for instrument air pressure low

1 No.

(iv)

Temperature Switches

a)

with the cylinder jacket for water

temperature high

1 No.

before the after-cooler for air

temperature high

1 No.

after the after-cooler for air

temperature high

1 No.

after the inter-cooler for air

temperature high

1 No.

b)

c)

d)

e)

(v)

with the reactivation air dryer for

reactivation air temperature low.

Flow Indicators

1 No.

a)

at the cylinder C.W. outlet for C.W. flow

1 No.

b)

at the after-cooler outlet for C.W. flow

1 No.

c)

at the inter-cooler outlet for C.W. flow

1 No.

d)

at the lubricating oil cooler outlet

for C.W. flow

e)

at the cooling water supply line to

Air Compressor for C.W. flow

1 No.

1 No.

(vi)

Level Gauges

a)

at the inter-cooler moisture separator

1 No.

b)

at the after-cooler moisture separator

1 No.

c)

at each air receiver.

(vii)

Vacuum gauge at the suction filter

1 No.

(viii)

Flow switch in the cooling water supply

line to air compressor unit to trip the
compressor in case of low flow of water.

1 No.

Indicating type flow switch in the

instrument air line to air receiver for
each unit to alarm high flow due to leakage.

1 No.

(ix)

(x)

Differential pressure gauge across oil filter.

1 No.

1 No.

The bidder shall include any other instrument required to make the system safe,
efficient and reliable.
2.8.18.6

Gear Boxes

Gear boxes containing helical gears, totally enclosed and lubricated shall be used for speed
reduction between motor drives and driven Equipments. (i.e. Compressors,
blowers, clinker grinders, combined ash slurry disposal pumps, scrapper
conveyors, etc.)
Gear boxes shall be totally enclosed and oil lubricated type. Positive lubrication shall be
provided to all the bearings and particularly to the working surface of the gear
teeth.
The gear unit shall be specifically designed for continuous service at the speeds
required by the application. Precision and accuracy of manufacture is essential
to minimise problems of vibration, impact stresses, noise distortions and
lubrication.
Dynamically balanced, helical gears shall be used.

i)

Casing
a)

The gearing shall be enclosed in an oil and dust proof gear case made of
closed grained cast iron or fabricated steel.

b)

The gear case shall be horizontally split and stress relieved before
machining. The faces of adjoining sections shall be accurately
machined to provide oil tight joints. Oil level gauges, drain, fill vent,
thermometer, dipstick and other required connections equipped with
approved mountings, valves and fittings shall be furnished for the gear
casing.

c)

The housing shall be generously proportioned and of rigid construction

to provide permanent alignment of rotating parts and protection from
possible external vibration. The arrangement shall be such that it will
be possible to lift gear case cover without disturbing the alignment of
shaft, gear and pinion.

The gear box shall be provided with suitable bearings of conservative design to
meet the worst duties under transients.
ii)

2.8.19

Rating of Gear Box

a)

Gear box shall be designed for heavy shock loads and while selecting a
gear box a service factor of minimum 2.0 shall be considered.

b)

The nominal mechanical KW rating of each gear box shall not be less
than the name plate KW rating of the selected drive motor.

c)

Thermal rating of each speed reduction gear box at 500C ambient

temperature shall not be less than the name plate KW rating of the
selected drive motor.

d)

For cooling of gear box, in case thermal capacity without auxiliary fan
is not sufficient to meet the thermal rating of gear box, necessary
auxiliary cooling fan shall be provided. Cooling coil for this purpose is
not acceptable.

e)

The selection of gear box shall be subject to Owners approval. The

Bidder shall furnish necessary calculations and selection charts for this
purpose for Owners review and approval.

Wetting Head
Adequately sized wetting head shall be provided above collector tank for wetting
the dry fly ash and separating it from conveying air, if any.
The wetting head shall be provided with a water supply of sufficient quantity and
pressure for feeding the nozzles that will produce fog spray of water, ensuring
rapid wetting of the incoming ash.
Nozzles shall be so directed as to prevent spray from entering the ash discharge
pipe.

The bidder shall elaborate as to have water vapour generated by the rise in water
temperature shall be prevented from rising from the wetting head into the
discharge chute to avoid the possibility of dry ash discharge pipe chute
blockage.
Wetting head shall be compact in design and provisions shall be made for easy
replacement of nozzles. Flanged connections shall be provided for all inlet and
outlet connections of the wetting head.
Material of construction shall be as follows:

2.8.20

(a) Body

Close grained 2% Nickel cast iron minimum hardness 250

BHN.

(b) Nozzle

Body of MS/Cast Iron and replaceable tip of Anti corrosion

tool steel or stainless steel of hardness 500-550 BHN. OR
Ceramic material.

Collector Tanks
The collector tank shall be located below the wetting tank and serve the purpose
to separate and vent out air and discharging the ash slurry to the combined ash
disposal sump through pipe lines. This will also serve the purpose of separating
and venting out the entrapped air discharged by wetting head and before
discharging the entrapped air into atmosphere, it shall be passed through an air
washer to achieve a sustained outlet dust emission of 50 Mg/Nm3 (Max.) with
the ash handling system operating at designed capacity. The dust emission
figure shall be guaranteed.
The collector tank shall be located at an elevation which will provide sufficient
static head to overcome frictional and other losses in the gravity flow discharge
line upto ash slurry sump.
For maintenance purposes suitable stair case, maintenance platform, walkway
with handrails at necessary levels shall be provided.
The sizing of collector tank, inlet/outlet connections etc. shall be corresponding
to the maximum anticipated discharge flow requirements. The collector tank
shall be complete with drain, overflow and vent pipe connections alongwith
pipes and requisite size and lengths.
The tank shall be internally lined with alloy C.I. liners of thickness not less than
20 mm.
The material of construction shall be as follows:
Tank

Tested quality, M.S. of minimum 10 mm thickness, as per IS:2062.

Baffle

Tested quality M.S., of minimum 12 mm thickness, as per IS:2062.

Liners

Alloy C.I. (300-350 BHN), 20 mm, thick minimum.