Saudi Aramco's Guide to Compressed Air Systems

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Compressed Air Systems
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not already
in the public domain may not be copied, reproduced, sold, given, or
disclosed to third parties, or otherwise used in whole, or in part, without
the written permission of the Vice President, Engineering Services, Saudi
Aramco.
Chapter : Process
File Reference: CHE10709
For additional information on this subject, contact

R. A. Al-Husseini on 874-2792
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CONTENTS
PAGES
INTRODUCTION ....................................................................................................................... 1
EQUIPMENT TYPES AND APPLICATIONS........................................................................... 2
Air Compression Package.............................................................................................. 2
Inlet Air Filter and Silencer ........................................................................................... 3
Compressor Type........................................................................................................... 4
Compressor Type Characteristics .................................................................................. 5
Compressor Controls ..................................................................................................... 5
Aftercooler..................................................................................................................... 8
Air Receiver................................................................................................................... 8
Air Dryer Installation................................................................................................... 10
Distribution Systems ................................................................................................... 11
Air Balances ................................................................................................................ 12
SYSTEM DESIGN CONSIDERATIONS ................................................................................. 14
System Demand........................................................................................................... 14
Typical Air Requirements............................................................................................ 15
Number and Size of Compressors ............................................................................... 15
Compressor Driver Selection....................................................................................... 15
Monitoring System Operation ..................................................................................... 16
Existing System Optimization ..................................................................................... 16
WORK AID 1: RELATIVE COMPRESSOR COSTS .............................................................. 18
WORK AID 2: FACTORS AFFECTING COMPRESSOR SELECTION ................................ 19
WORK AID 3: COMPARISON OF COMPRESSOR TYPE FEATURES ............................... 20
WORK AID 4: MOISTURE CONTENT OF COMPRESSED AIR .......................................... 21
WORK AID 5: TYPICAL PLANT AIR REQUIREMENTS FOR PNEUMATIC
TOOLS*.................................................................................................................................... 23
WORK AID 6: INSTRUMENT AIR CONSUMPTION ........................................................... 24
GLOSSARY.............................................................................................................................. 25
REFERENCES.......................................................................................................................... 26
Saudi Aramco Standards.............................................................................................. 26
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Saudi Aramco Design Practices ................................................................................... 26

Exxon Basic Practices.................................................................................................. 26
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INTRODUCTION
See Saudi Aramco Standard SAES-J-901.
There are several uses for compressed air in a plant. Many valves and instruments are pneumatic. Maintenance
and construction tools often require compressed air as a power source. Air is required in some processes. It is
used for decoking furnaces and for regenerating some catalysts and desiccants.
Figure 1 shows a typical compressed air system with two air compressors. Each compressor has inlet air filters
and silencers and outlet air coolers. There is an air receiver where some moisture is removed. The receiver
acts as a surge drum in the system to maintain system pressure during short outages.
Figure 1. Compressed Air System Simplified Flow Plan

Downstream of the air receiver, the system splits into two systems. One is called the utility air system. This air
is distributed without drying. The other is called the instrument air system. This air is filtered and dried before
distribution.
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EQUIPMENT TYPES AND APPLICATIONS

The equipment included in a compressed air system consists of the air compression package, air coolers, air
receivers, air dryers, and distribution piping.
Air Compression Package

Components that are typically included in an air compression package are:
An air filter and silencer
A compressor and gear if required
A driver with a coupling
Intercoolers with moisture separators and automatic water removal
A lube oil system
Suction throttle valve and discharge check valve
Discharge blowoff valve and silencer
Vibration monitoring system
Controls and instrumentation
Figure 2 shows how these components are connected. This illustration is for a centrifugal compressor, which
requires a suction throttle valve and a discharge blowoff valve. The suction throttle and discharge blowoff
valves are not required for a reciprocating compressor.
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Figure 2. Compressed Air System Air Compression Package

Inlet Air Filter and Silencer
An inlet air filter removes dust, dirt, sand, and other abrasive or gritty particles. Filtering prevents damage to
the compressor and minimizes maintenance and downtime. The silencer removes the objectionable air inrush
noise.
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Compressor Type
There are two ways to increase the pressure of a gas. One is to reduce the volume of the gas. The other is to
increase the velocity of the gas. Positive displacement compressors reduce the gas volume. There are several
different types of positive displacement compressors. They include:
Reciprocating
Rotary or helical screw, or rotary lobe
Sliding vane
Liquid piston
Diaphragm
Of these, reciprocating compressors and rotary screw or helical screw compressors are most often used in gas
plant and refinery compressed air systems.
Centrifugal compressors and axial compressors increase pressure primarily by increasing the gas velocity.
Centrifugal compressors are more often used in compressed air systems.
Capacity and discharge pressure are the key factors in selecting a compressor. Helical screw compressors can
have a high capacity but are limited in discharge pressure to about 250 psig. Reciprocating compressors can
have a high discharge pressure but are limited in capacity. A typical guideline is to consider reciprocating
compressors up to 1,500 SCFM and centrifugal or screw compressors above 2,000 SCFM. Saudi Aramco
prefers centrifugal compressors above 900 SCFM.
All instrument-air compressors in the Saudi Aramco facilities must be of the oil-free type.
Work Aid 1 gives an approximation of the relative cost of various types of air compressors versus the
compressor capacity in SCFM.
Other factors influence the selection of a type of compressor. These include:
Efficiency
Noise
Sensitivity to fouling and solids
Availability or reliability
Maintenance requirements and costs
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Compressor Type Characteristics

Reciprocating compressors tend to have higher maintenance costs, lower availability, and the poorest
sensitivity to fouling and solids. However, they are lower in cost in smaller sizes.
Centrifugal compressors tend to have lower maintenance costs, higher availability, higher efficiency, and
lower noise levels. They are also lower in cost in large sizes.
Work Aid 2 summarizes the main factors to be considered in selecting a compressor type. Work Aid 3
compares the features of five types of compressors on a scale of 1 to 10.
The final selection depends on the result of an over all economic analysis.
Compressor Controls
Controls are provided in an air compressor package to:
Regulate the flow of air to match the demand
Prevent surging of a centrifugal compressor
Regulate the discharge pressure
Automatically start spare compressors
Protect the compressor and driver from damage
Two methods are commonly used for regulating the compressor flow and discharge pressure. The conventional
method with reciprocating compressors is a multistep load and unload method.
With a centrifugal compressor, a two-step load and unload operation is also possible. However, capacity
modulation with suction throttling has several advantages. Most variations in air demand can be
accommodated within the throttling capacity of the control system. A constant discharge pressure can be
maintained. Power demand is lower because no air is wasted down to the surge point, or about 70% of
capacity. There are power savings down to zero air delivery.
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Figure 3 illustrates a control system for two reciprocating air compressors, one motor-driven and one steamturbine-driven. A common discharge pressure controller loads or unloads the cylinders of the operating
compressor to control the discharge pressure. A hand selector switch is included to indicate which compressor
will normally run and which will be on standby. A low-pressure cut-in control is included to start the standby
compressor if discharge pressure drops below a set point. In this figure, it is set at 110 psig.
Figure 3. Compressed Air System - Simplified Control

System for Reciprocating Compressors
Another pressure controller will start to shut off air to the utility air system if the discharge pressure drops to
100 psig. It will shut off utility air completely if the discharge pressure drips to 90 psig.
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Figure 4 shows a different control scheme for two centrifugal compressors. One is motor-driven and the other
is steam-turbine-driven. The common discharge pressure controller throttles the suction of the operating
compressor to control the discharge pressure by controlling the air flow. On the discharge of each of the
compressors, a flow recorder controller (FRC) is set 10% above the surge flow of the compressor.
Figure 4. Compressed Air System - Simplified Control System for Centrifugal

Compressors
If the suction throttle valve reduces the compressor air flow to the FRC setting, a discharge blowoff valve will
start to open to ensure that flow stays above the surge point.
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This control scheme also has a hand selector switch to select the normal and standby compressor and automatic
cut-in of the standby compressor on low discharge pressure. The pressure cutoff for the utility air system is the
same as for the reciprocating compressor.
Aftercooler
The function of an aftercooler is to cool the compressed air after it has been compressed. Saudi Aramco
specifies that compressed air must be cooled to 140F or below. This cooling will condense up to 60% of the
incoming water vapor. It will reduce the volumetric flow of air to downstream equipment and protect
downstream equipment from overheating.
Two types of aftercoolers are in common use. One is shell-and-tube exchangers using cooling water or air fins
where ambient temperatures are low enough. Water-cooled exchangers are more common than air-cooled.
They can be used in any climate, are usually less expensive, take less space, and are less noisy.
Air cooled exchangers save water and generally require less maintenance. However, they are more expensive.
Also they are limited in cooling to about 15F above ambient temperature or higher.
Air Receiver
An air receiver provides continuity of air flow during surges in demand, compressor trips, and loading and
unloading. An air receiver provides a large volume to entrap and remove condensed water vapor and oil. It
will also provide some time (usually a minimum of one minute and often two to three minutes) for operators to
take corrective action following loss of all compressors.
A typical standard for sizing an air receiver is to provide a minimum of one minute of base instrument air load
while the air receiver pressure decays from 100 psig to 50 psig. This standard applies to systems that have
standby compressors started automatically. For systems with manual-start compressors, this time can increase
to as much as 15 minutes.
It is common to have only one or two air receivers at an air compressor house where several compressors are
installed. However, in some plants, air receivers are installed at other locations. For example, at Saudi
Aramco, receivers are installed at most air-operated valves.
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The following equations are used to determine the volume of an air receiver.
V
= Volume of receiver, ft3
t
= Time in minutes the receiver will supply air from upper to lower pressure limits
C
= Air flow rate, SCFM
T
= Air temperature, Rankine
P1
= Upper pressure limit, psig
P2
= Lower pressure limit, psig
For example, if the air demand for a Saudi Aramco plant is 3,000 SCFM, the receiver volume would be
calculated as follows:
t
= 1 minute
Where
3,000 SCFM
140F + 460 = 600R
P1
100 psig
P2
50 psig
Work Aid 4 is a nomogram for determining the amount of moisture that enters an air compressor and the
moisture remaining in air leaving the air receiver. The nomogram is based on isothermal compression; that is,
the air leaving the air receiver is assumed to be the same temperature as the air entering the compressor.
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For example, assume inlet air is 120F at 40% humidity and air leaving the aftercooler is also at 120F and 125
psig. To use the nomogram, first connect 120F on the T scale with 40% on the R scale. Where the line
crosses the M-1 scale, read the moisture per 1,000 SCF of inlet air. This is about 2.0 lb per 1,000 SCF.
Next, align 2.0 on the M-1 scale with 125 psig on the P scale. Read the moisture in 1,000 SCF of 125 psig air
at 120F. This is about 0.2 lb per 1,000 SCF. That is, the air now contains only 10% of the water vapor
originally taken into the compressor (0.2 divided by 2.0) x 100 = 10%. Therefore, 90% of the moisture was
removed by intercooling and after cooling to 120F.
Air Dryer Installation

An air dryer installation usually includes a prefilter, a dryer, and an afterfilter. The total installation pressure
drop should be less than 5 psi at maximum design flow rates. The prefilter removes liquid oil and water and
solids to protect the dryer desiccant. The prefilter is usually designed to remove 98% of all oil droplets greater
than 1 m in diameter. Oil retention is usually 2 lb for each 100 SCFM of design capacity. The filter material
typically is activated carbon or alumina. The filter should have an automatic drain.
The afterfilter removes fragmented or pulverized desiccant from the dried air. It is designed to remove 100% of
all particles larger than 1 m in diameter. The afterfilter is usually a dual cartridge filter to allow cleaning
without shutdown or bypassing.
An air dryer keeps compressed air, particularly instrument air, free of water. This is necessary to avoid
instrumentation malfunction and damage. Dry air keeps maintenance low, reduces pneumatic equipment
downtime, and minimizes upsets in temperature controls, flow, and other process units.
The four main types of air dryers are heat-regenerated absorption, non-heat-regenerated absorption,
refrigeration, and rotary absorption dryers.
The heat-regenerated and non-heat-regenerated absorption dryers are similar except for the regeneration system.
Both types consist of two desiccant filled chambers connected in parallel. The desiccant in one of the chambers
dries the air stream while the desiccant in the other chamber is being regenerated.
In the heat-regenerated dryer, air is heated with medium-pressure steam or other heat medium. The hot air then
is used to purge moisture from the spent desiccant. Silica gel or alumina is used as a desiccant. These dryers
are relatively expensive to purchase and to operate.
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In the non-heat-regenerated dryer, regeneration is carried out under vacuum using dry air for purging. Purging
can require from 3 to 15% of the dryer capacity. Saudi Aramco prefers heatless regeneration, desiccant-type
dryers.
The rotary absorption dryers dry by the chemical reaction of desiccants to form hydrates or hydroxides. They
are rarely if ever used to dry plant air.
The design dewpoint for air from a dryer is often specified as 20F below the minimum recorded temperature at
a plant. At Saudi Aramco, the design dewpoint is 4F. Dewpoint is one of the key factors in selecting the
type of air dryer in many locations. The table below gives typical dewpoints that can be obtained by the
various dryer types:
Dryer Type
Refrigeration
Minimum Dewpoint (F)

at 125 psig
35
Heat-regenerated absorption
40 to 60
Non-heat-regenerated absorption
40 to 100
The number of compressors and dryers varies greatly from plant to plant. Some large industrial plants have
only two air compressors and one air dryer.
At Ras Tanura, there are two compressor houses, North and South, each with five compressors. Three
compressors in each house are motor driven and two are 600-psig steam-turbine driven. In the North House,
the compressors are 1,500 SCFM each, and there are three 1,500 SCFM dryers. In the South House, the
compressors are 1,700 SCFM each, and there are two 1,700 SCFM dryers. In addition to these compressors,
there is one special 900 SCFM emergency diesel-driven compressor for utility air.
Distribution Systems
In most industrial plants with compressed air systems there are at least two separate systems. One supplies
instrument air, which is dried. The other supplies plant or utility air, which is not dried.
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At Ras Tanura, there are two instrument air systems; one is for utility instruments and the other is for refinery
instruments. Instrument air is dried and oil free. In Saudi Aramco, the instrument air systems operate between
125 psig maximum and 75 psig minimum. The instrument air systems are looped so that sections of the
distribution piping can be removed from service without cutting off instrument air.
At Ras Tanura there are two additional air systems that are not dried: the plant air system and the process air
system. Plant air is used for pneumatic tools, maintenance, and at utility stations. Process air is used for
decoking, catalyst regeneration, and other process requirements.
Normally, instrument and plant air are distributed at the same pressure. There are exceptions at some plants for
different specific reasons. The distribution system usually is sized to provide a minimum of 75 psig at the most
distant consumer from the compressed air source at maximum demand flow rate. The total pipeline pressure
drop should not exceed 5 psi at this maximum demand flow rate.
Air Balances
Plant air balances are very useful for designing, operating, and analyzing a plant air system. Balances should
be prepared for all normal and extreme situations including:
Normal operation
Peak demand
Upset and emergency situations
Seasonal variations, if any
Turnarounds and regenerations
An air balance summarizes the air production and air consumption unit by unit. The air balances are used for:
Establishing or verifying the capacity of various system components
Developing operating techniques to handle upsets and emergencies
Establishing a basis for selecting a load-shedding scheme
Optimizing the use of air within a system
Checking the operating flexibility of a system
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An example of an air balance is shown on here.
Consumer
AF 1
AP 1
VP 1
NH 1
SL 1
PF 1
AP 1 Treating
CC 1
CL 1
AL 1
AM 1
SU 1
CC 1 Treating
OF 1
OM 1 & 2
UP
Instrument Air SCFM

Maximum
40
150
100
35
70
175
15
290
100
160
60
5
60
59
70
270
1,659
Plant Air SCFM

Normal
Maximum
1,060
575
965
960
1,440
210
2,640
425
34
____
1,629
900
4,069
From this balance, the base system air demand would be the sum of the instrument air maximum and plant air
normal loads or 1,659 + 1,629 = 3,288 SCFM. The maximum demand on the system would be the sum of the
maximum instrument air load and the simultaneous maximum plant air load or 1,659 + 4,069 = 5,728 SCFM.
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SYSTEM DESIGN CONSIDERATIONS

System Demand
The compressed air system demand includes air requirements for instruments, maintenance, and processes. The
instrument air demand is usually a relatively steady load. It is estimated on a unit-by-unit basis.
The maintenance air demand is sometimes called utility air, plant air, or yard air. It is a highly fluctuating load.
Demand estimates are usually not precise. The maintenance air demand often peaks during a plant or unit
turnaround.
The process air demand may also be highly fluctuating. It is normally estimated by the designers of the
individual unit. It can be included as part of the utility, plant, or yard air systems. Process air demands often
peak during a decoking or regeneration operation.
To establish the compressed air demand, you need to tabulate normal and maximum instrument and plant air
loads. Add appropriate load growth factors to account for anticipated or unexpected future loads. Also add
reserve or spare capacity factors to account for inaccuracies in estimates.
Saudi Aramco standards call for a minimum reserve air space capacity of 50% for plant instrument air if 80% of
a plant's control loops are electronic. This spare capacity drops to 20% if 80% of the control loops are
pneumatic. Also, where heatless dryers are used, an additional 20% of the plant capacity is required to provide
for dryer regeneration.
In addition, Saudi Aramco requires additional compressor capacity to account for compressor wear. For
centrifugal compressors, 10% additional capacity is required. For reciprocating compressors, 50% additional
capacity is required.
Nonessential or less critical loads can be shed as a means to protect more critical loads. For example, Ras
Tanura has two instrument air systems, a plant air system and a process-air system. If a problem results in loss
of compressed air pressure, a load-shedding sequence is started. At 90 psig the plant air system is shed. If
pressure continues to fall, the process air system is shed at 80 psig. Next, the refinery instrument air system is
shed at 75 psig. This keeps the utility instrument air system in service as long as possible.
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Typical Air Requirements

Work Aids 5 and 6 list some typical values for instrument air consumption and plant air consumption. You can
use Work Aid 6 when better information is not available. Work Aid 5 gives typical air requirements for various
pneumatic tools.
Number and Size of Compressors

In general, economics favor using a small number of high-capacity compressors. This requires minimum space.
Control and operations are easier. High capacity compressors are available at a lower per unit cost than smaller
compressors. Many new industrial plants will have only two 100% or three 50% capacity compressors. This is
not always true. For various reasons, such as staged expansion of a plant, a large geographical area, or for
reliability, more compressors may be installed.
The size of the compressed air system is very important. If a system is too small, it will not be able to maintain
the required pressure at maximum demand. If it is too large, it will be inefficient at partial load. The system
should be able to handle the peak air demand and the base air demand efficiently. The peak demand is the sum
of the maximum instrument air demand and the maximum plant air demand. The base demand is the sum of
the maximum instrument air demand and the normal plant air demand.
It is customary to meet the peak demand with all installed compressors operating without load shedding. This
peak demand is intermittent. It is often scheduled. If the peak demand can be scheduled enough in advance, a
portion could be met by rental compressors or compressors brought in from other locations.
It is also customary to design to meet the base demand with the largest compressor in the system out of
operation for maintenance. If a peak demand should occur with the largest compressor out of service, load
shedding of less critical loads would be necessary.
Compressor Driver Selection

Common drivers used with a compressor are electric motors, steam turbines, and diesel or gas engines. The
selection of driver types is based on system reliability, economics, compatibility with the plant steam balance,
and the availability and reliability of an electric power supply.
Typically, at least one motor driver and one steam turbine driver are selected to improve the overall system
reliability. Often, a standby engine-driven compressor is also installed to provide air during a total steam and
power outage.
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Monitoring System Operation

The significant parameters to monitor in a compressed air system are the moisture in the air, the air pressure and
temperature, and the air compressor operation.
Each air system will have a continuous moisture or dew point analyzer to monitor air dryers. It will indicate the
moisture removal efficiency of a regenerated dryer and when a dryer should be regenerated. Spot checks
should also be made of the moisture content of the inlet air as well as at key points throughout the instrument
air system. Spot checks can indicate potential problems such as a collection of water in distribution system low
points.
Each main plant air receiver will have pressure instruments and a low pressure alarm to indicate whether the
system pressure control is functioning properly. Spot checks of pressure at several critical points throughout
the air distribution system should be made. These will indicate potential plugging of a line or excessive usage
in an area of the plant.
Temperatures should be monitored downstream of intercoolers and aftercoolers to make certain that the coolers
are functioning properly.
Each compressor should be checked frequently for satisfactory operation. For reciprocating compressors,
cylinder head temperatures and lube oil pressures should be monitored. For centrifugal compressors, vibration,
bearing temperatures, lube oil pressure and lube oil temperature should all be checked. Machinery specialists
should be consulted if any readings differ from normal.
Existing System Optimization

In an existing system, improvements may be possible. As systems age, many air leaks may develop. These
should be repaired.
The use of air for some services may no longer be required. Air for cleaning, cooling, or purging may be
reduced or eliminated.
Some consumers may have been unnecessarily connected to the instrument air system when plant air would be
adequate. These can be reconnected. Also, air supplies to utility stations can be limited by restriction orifices
to reduce unnecessary or excessive use.
Compressor operation can be optimized. An economical driver selection can be made depending upon the
plant steam balance. A compressor can be base loaded with variations taken on another compressor. If
compressors are of different sizes, the compressors that fit the demand best can be selected. Unnecessary
compressors can be shut down. Portable compressors can be used to supply scheduled peak demands.
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Air filters should be kept clean. Steam releases near compressor suctions should be minimized. This will
reduce the power requirement for the compressors since the suction air will be cooler and drier. The purge air
for dryer regeneration should be controlled as well as the drying time, to avoid wasting of compressed air.
Avoid excessive drying of air to very low dewpoints if not required.
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WORK AID 1: RELATIVE COMPRESSOR COSTS

The following graph shows the relative costs of five types of compressors in relation to required capacity. For
example, at 1,500 SCFM, a lubricated reciprocating compressor would cost approximately 110% of base,
whereas a centrifugal compressor would cost nearly 150% of base.
Figure 5. Relative Compressor Costs
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WORK AID 2: FACTORS AFFECTING COMPRESSOR SELECTION
Common
Mechanical
Efficiency
Sensitivity
to Fouling
& Fine
Solids
Relative
Noise
Generation
Level
Relative
Sensitivity
to Liquid
Mist CarryOver
Relative
Maintenance
Requirements
0.70-0.80
0.99
Medium
Medium
Medium
Low
0.997
Non-Lubricated
Reciprocating
0.75-0.90
0.94
Very High
High
High
Very High
High Pressure
Helical Screw
0.74-0.78
0.96
Low
Very High
Low
Medium
Compressor
Type
Common
Compression
Efficiency
Range
Conventional
Centrifugal
Availability Factor
Clean
Fouling
Service
Service
Maintenance Costs
Mat'l
Lab
Relative
0.995
20%
80%
Base
0.960
35%
65%
4 x Base
0.995
0.990
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WORK AID 3: COMPARISON OF COMPRESSOR TYPE FEATURES
Compressor Characteristics
Lubricated
Dry
Reciprocating Reciprocating
Lubricated
Screw
Dry
Screw
Centrifugal
High Life Expectancy
10
Oil-Free Air
10
10
10
Low Installation Cost
10
10
Low Foundation Cost
10
10
10
High Long Term Efficiency
10
High Part Load Efficiency
Low Regular Maintenance
10
Ease of Inspection
10
Quietness of Operation
Freedom from Vibration
10
10
10
Safety
10
Capability of Uprate
10
NOTE:
1) Gradings against all items except the price are a guide to the capabilities of the 5 types of compressors.
The scale is from 0 to 10 with 10 being the "best" grading.
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WORK AID 4: MOISTURE CONTENT OF COMPRESSED AIR

NOTE: Work Aid 4 is a two page reprint from Oil, Gas & Petrochem Equipment. The first page explains how
to use the nomogram which is on the second page.
Bill Sisson
Pryor, OK
This NOMOGRAM shows the effects of various ambient temperatures and relative humidities on the quantity
of moisture in atmospheric air entering a compressor at 14.7 psia and on the moisture remaining in saturated air
that is compressed isothermally to the pressures shown.
This monogram may be used to find several different values.
Example No. 1. What is the moisture content of 1,000 cu ft of incoming air at 80F and 60% relative
humidity? At what temperature can condensation be expected in a low pressure cylinder pumping this air to 25
psig?
Solution (solid lines). Step 1, connect 80 on T scale with 60% relative humidity on R scale and read moisture
content of incoming air as 0.95 lb/1,000 cu ft of air at intersection with M-1 scale. Also mark where line
crosses M-2 scale. Step 1, align marked point on M-2 scale with 25 psig on P scale, extend line to T scale and
read temperature at which condensation can be expected as 97F to prevent condensation on cylinder walls.
Example No. 2. Temperature of saturated air at compressor intake (0 psig) is 80F. How much moisture is
contained in 1,000 cu ft of this air? If compressed to 100 psig, and cooled to 80F, how much moisture is
contained in 1,000 cu ft of the air?
Solution (dashed lines). Step 1, connect 80F on T scale with 100% on R scale and where line crosses M-1
scale read moisture per 1,000 cu ft of inlet air as about 1.58 lbs. Step 2, align 1.58 on M-1 scale with 100 psig
on P scale and read moisture in 1,000 cu ft of air as 0.20 lb where line crosses M-2 scale.
That is, the air now holds only 12.66% of the water vapor originally taken into the compressor [(0.20/1.58) x
100 = 12.66%]. Or, 87.34% (100 12.66 = 87.34) of the original moisture has been removed by cooling the
air to 80F.
With permission from Oil, Gas & Petrochem Equipment.
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Figure 6. Moisture Content of Compressed Air

With permission from Oil, Gas & Petrochem Equipment.
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WORK AID 5: TYPICAL PLANT AIR REQUIREMENTS FOR PNEUMATIC

TOOLS*
Description of Tool
Hand Grinders
1-1/2" Wheel
2" Wheel
4" Wheel
6" Wheel
8" Wheel
Hand Riveters
4" Stroke
5" Stroke
6" Stroke
8" Stroke
10" Stroke
Riveting Machines
Rivet Busters
Hand Sanders
7"
9"
Chipping Hammers
1-1/2" to 4"
Scaling Hammers
Air Hoists
500-1,000 lb
2,000 lb
3,000 lb
4,000 lb
6,000 lb
Geared Hoists
1 Ton
1-1/2/ Ton
2
3
4
5
6
8
10
Impact Wrenches
1/4" Size
3/8"
5/8"
3/4"
1-1/4"
1-3/4"
SCFM
12
16
28 to 35
40 to 45
50 to 60
32
34
37
38
40
50
55 to 60
35
45
20 to 25
15
0.5
2
3.2
6.3
8.4
Per ft Lift
3
5
6
8
10
15
20
25
30
8 to 9
12
22
28
38
50
Description of Tool
Jacks
Cylinder Diam. In.
9
10
12
14
16
20
24
Air Motors
2 hp
4
5
8
15
Rotary Steel Drills
1/4" Drill Size
1/2"
5/8"
7/8"
1"
1-1/4"
2"
Screwdrivers
Nut Runners
1/4" Bolt Size
3/8"
1/2"
3/4"
1"
Sand Blasting Equipment
Nozzle Size lb/h Sand
3/16"
500
1/4"
900
3/8"
1,700
1/2"
3,000
Tube Cleaners
SCFM
1.8
2.8
4.0
5.0
6.9
11.1
16
40 to 50
60 to 70
90 to 100
140
240
20
28 to 32
36 to 42
55
65
85
90
12 to 20
12
22
38
42
46
50
90
210
375
200
*Average SCFM of 90 psig air
23
Process
WORK AID 6: INSTRUMENT AIR CONSUMPTION

See SAES-J-901.
0.5 SCFM for each consumer if better data not available
Transmitters
Controllers
Manual load stations
Computing relays
0.75 SCFM for diaphragm control valve with positioner
5.00 SCFM for piston valve with positioner
Typical instrument loop includes transmitter, controller, and valve positioner
Positioners use more when stroking (7-10 SCFM) but average can be assumed to be 1 SCFM
Allow 10% for purges and leaks
In electro-pneumatic loops, consumers are transducers and valve positioners
Air motors
Gate
SCFM
SCFM of 100 psig air
Max valve pressure drop, psi
Nominal valve size, inches
Time to move valve between extremes, sec
Pd 2 d
Globe (control ) valves SCFM = 6 +
220 t
24
Process
GLOSSARY
aftercooler
air receiver
axial compressor
centrifugal compressor
intercooler
reciprocating compressor
rotary compressor
Air cooler at the discharge of a compressor that cools the air and lowers the
dewpoint as moisture in the air condenses.
Drum in an air system that provides a calculated volume to absorb air
surges and provide an air volume as pressure decays from an operating
pressure to a lower minimum acceptable pressure. This helps to provide air
flow continuity during compressor trips or loading and unloading.
A dynamic machine that develops pressure by accelerating a gas in an axial
direction and converts the resultant high velocity to pressure.
A dynamic machine that develops velocity of a gas by centrifugal force,
with flow in the radial direction, and converts the resultant high velocity to
pressure.
Air cooler located between stages of a compressor.
A compressor with one or more reciprocating cylinders displacing a
positive volume with each stroke.
Positive displacement compressor that employs mainly rotary motion.
Rotary compressors can be of lube, screw, cane and liquid-ring types.
Each type has a casing and one or more rotating elements that either mesh
with each other, such as lubes or screws, or that displace a fixed volume
with each rotation.
25
Process
REFERENCES
Saudi Aramco Standards
SAES-J-901
Instrument Air Supply Systems
SAES-K-402
Centrifugal Compressors
SAES-K-403
Reciprocating Compressors
Saudi Aramco Design Practices
SADP-K-402
Centrifugal Compressors
SADP-K-403
Reciprocating Compressors
SADP-K-605
Inlet Air Filtration for Rotating Equipment
Exxon Basic Practices
BP10-3-3
Rotary Screw Compressors

BP10-4-2
BP15-6-1
Reciprocating Compressors for Utility and Instrument Air Systems
Electronic and Pneumatic Instruments
26

Saudi Aramco's Guide to Compressed Air Systems

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Saudi Aramco's Guide to Compressed Air Systems

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Compressed Air Systems

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Saudi Aramco DeskTop Standards

Saudi Aramco Design Practices ................................................................................... 26

Saudi Aramco DeskTop Standards

Figure 1. Compressed Air System Simplified Flow Plan

Saudi Aramco DeskTop Standards

EQUIPMENT TYPES AND APPLICATIONS

Air Compression Package

An air filter and silencer

A compressor and gear if required

A driver with a coupling

Intercoolers with moisture separators and automatic water removal

A lube oil system

Suction throttle valve and discharge check valve

Discharge blowoff valve and silencer

Vibration monitoring system

Controls and instrumentation

Saudi Aramco DeskTop Standards

Figure 2. Compressed Air System Air Compression Package

Saudi Aramco DeskTop Standards

Rotary or helical screw, or rotary lobe

Sensitivity to fouling and solids

Maintenance requirements and costs

Saudi Aramco DeskTop Standards

Compressor Type Characteristics

Regulate the flow of air to match the demand

Prevent surging of a centrifugal compressor

Regulate the discharge pressure

Automatically start spare compressors

Protect the compressor and driver from damage

Saudi Aramco DeskTop Standards

Figure 3. Compressed Air System - Simplified Control

Saudi Aramco DeskTop Standards

Figure 4. Compressed Air System - Simplified Control System for Centrifugal

Saudi Aramco DeskTop Standards

Saudi Aramco DeskTop Standards

140F + 460 = 600R

Saudi Aramco DeskTop Standards

Air Dryer Installation

Saudi Aramco DeskTop Standards

Minimum Dewpoint (F)

Saudi Aramco DeskTop Standards

Upset and emergency situations

Seasonal variations, if any

Turnarounds and regenerations

Establishing or verifying the capacity of various system components

Developing operating techniques to handle upsets and emergencies

Establishing a basis for selecting a load-shedding scheme

Optimizing the use of air within a system

Checking the operating flexibility of a system

Saudi Aramco DeskTop Standards

An example of an air balance is shown on here.

Instrument Air SCFM

Plant Air SCFM

Saudi Aramco DeskTop Standards

SYSTEM DESIGN CONSIDERATIONS

Saudi Aramco DeskTop Standards

Typical Air Requirements

Number and Size of Compressors

Compressor Driver Selection