418-250-D00-Q2-001 (Calculation For Compressed Air Package - Rev.01)

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 1 of 8

 

BASIS DESIGN CALCULATION REPORT FOR COMPRESSED AIR PACKAGE 

01 

13/08/2012

ISSUED FOR APPROVAL

H.GH

S.S.K. 

M.M. 

R.A. 

00 

24/06/2012

ISSUED FOR APPROVAL

H.GH.

S.S.K. 

M.M. 

R.A. 

REV. 

DATE 

DESCRIPTION 

DESIGNER 

CHECKED 

 APPROVED  

P.M 

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 2 of 8

 

TABUL ATION OF REVISE REVISED D PAGES PAGE

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Rev.00

Rev.01

Rev.02

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Rev.04

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 3 of 8

 

1.  Introduction Present calculation defines minimum requirements for design and selection of compressed air production station equipments to provide compressed air for  process

& instrument purpose to use in Sarcheshmeh Converter Off Gas

 Handling  Project (Kerman  Handling  Project (Kerman Province) – IRAN. The production shall be Oil-Inject with dry compressed air. Compressor room mainly consist of 3 rotary screw and Oil inject type compressor (Two sets in operation and one set stand-by), One air receiver, set of dryers (adsorption or desiccant), set of filters, Water Separators, piping with all accessories, set of instruments, cabling for power and instrumentation with accessories. Air compressor system must be designed according to ISO 8753-1, class 5.2.5 for Plant Air & 2.2.3 for Instrument Air

2.  Site Location & Climatic Condition Geographical location

Elevation

Iran, Sarcheshmeh 2450 m (a.s.l.)

Latitude

North 29.950 º

Longitude

East 55.850 º

Location

Climatic Conditions Highest / Lowest Recorded Temperature

+ 35°C / -25 °C

Highest / Lowest Lowest Design Temperature Temperature

+32.5 °C / -17.7 °C

Annual Average Rainfall

400 mm / a

Barometric Pressure

564.4 mm Hg

Humidity of Air

24% @ 33 °C

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

 

3. 

Design Data

3.1.  Service conditions Gas Handled  Discharge

 Natural air 7.5 bar(g)

 Pressure  Average Flow  Rate (At package  outlet)

3105 Nm³/hr

 Plant Air (flow)

3050 Nm³/hr @ 6 bar(g)  bar(g) 

 Instrument air (flow)

55 Nm³/hr @ 6 bar(g)

Operation

Continuous

 Noise Limit at 1 m

75 dB(A)

Cooling System

Air cooled

 Air Tank

12000 Lit.

 Air Quality

ISO 8753-1, class 5.2.5 for Plant Air & 2.2.3 for Instrument Air  

Page 4 of 8

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 5 of 8

 

4.  Calculations 4.1. 

Location: Sarcheshmeh

4.2. 

Site Condition:

Min. / Max. Ambient Temperature:

-25 / +35

°C

Altitude:

2450

masl

Relative Humidity:

44

% Ave.

4.3. 

Calculation of Rotary Screw Air Compressor Capacity:

1)  Compressor Air Flow Rate:

3105

Nm³/hr

2)  Plant Air Flow Rate:

3050

Nm³/hr

3)  Instrument Air Flow Rate:

55

Nm³/hr

4)  Desiccant air dryer losses:

20

% (ref. to heated type

air dryer without blower & -40°C atmospheric dew point) 5)  Altitude & Temperature effect correction factor: Air pressure at 2100 masl:

0.75

bar a

Air pressure at sea level:

1.013

bar a

55 Nm³/hr x 1.20 = 66 Nm³/hr 3105 Nm³/hr

(Desiccant air dryer capacity without correction factors)

(Air compressor capacity without site condition correction factors)

Qc = Qn x ((273 + Ti) x Po) / (273 x Pi) Qc = 3105 x ((273 + 35) x 1.013) / (273 x 0.75) Qc = 3105 x 1.524 = 4732 m³/hr = 78.87 m³/min

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 6 of 8

 

78.87 m³/hr x 1.15 (Over Design) = 90.7 m³/min 90.7 m³/hr ÷ 2 = 45.35 m³/min

Three compressors are needed, Two are in operation and One is stand by

4.4. 

Calculation for Desiccant Air Dryers Sizing:

All air dryers (adsorption & refrigerant types) flow rate are based on 1 bar (a) and 20 °C ambient conditions & 7 bar (g) and 35 °C inlet temperature at 100% RH. This is standard condition. To choose a dryer on a given flow at non-standard operating condition, divide the given flow by an appropriate correction factor(s). Dryer inlet pressure:

8 barg (Max.)

→ c.f.1

= 1.12

Dryer inlet temperature:

45 °C

→ c.f.2

= 0.7

C.F. = c.f.1 x c.f.2 = 1.12 x 0.7 = 0.784 66 Nm³/hr ÷ 0.784 = 84.2 m³/hr = 1.4 m³/min

4.5. 

Calculation for Refrigerant Air Dryer Sizing:

Dryer inlet pressure:

8 barg (Max.)

→ c.f.1

= 1.06

Max. Ambient temperature:

35 °C

→ c.f.2

=1

Dryer inlet temperature:

45 °C

→ c.f.2

=1

Dryer dew point:

+5 °C

C.F. = c.f.1 x c.f.2 = 1.06 x 1 = 1.06 3050 Nm³/hr x 1.524 = 4648 m³/hr (F.A.D.) 4648 m³/hr ÷ 1.06 = 4385 m³/hr

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

Date: 13/08/2012

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Page 7 of 8

 

4.6. 

Calculation for Micro Filters Sizing:

Operation pressure:

8 barg

→ C.F.

= 1.1 (7 barg

→ C.F.

= 1)

 Note: Pre-Filter inlet pressure is about 8 barg and dust-filter outlet pressure will be less than 8  barg (about 7.5 barg in dry dry state and 7 barg in wet state), so we select a correction factor of 1 in order to better performance. a)  Desiccant dryer filters: 66 m³/hr ÷ 1 = 66 m³/hr

 b)  Refrigerant dryer filters: 4385 m³/hr ÷ 1 = 4385 m³/hr

4.7. 

Calculation for Plant Air Receiver Sizing:

Capacity of Plant Air Receiver is calculated as follow and the volume intended for this purpose is 41 m³ based on providing 3 minutes supply of 3217.6 STD m³/hr air while depressurizing from 8 barg to 4barg. V = (Q x Time x Po) / (Pu – Pl) = (53.63 x 3 x 1.013) / (8 – 4) = 40.75 m³

The buffer(s) will be installed after air compressors.

4.8. 

Calculation for Instrument Air Receiver Sizing:

Capacity of Instrument Air Receiver is calculated as follow and the volume intended for this  purpose is 5 m³ based on providing 15 15 minutes supply of 58 STD m³/hr air while depressurizing from 7 barg to 4barg. V = (Q x Time x Po) / (Pu – Pl) = (0.97 x 15 x 1.013) / (7 – 4) = 4.9 m³

The buffer will be installed after air dryer.

 

Sarcheshmeh Converter Off Gas

 

Handling Project Consultant:

 Document No:

Rev.

 418/250-D00-Q2-001

 01

 Tadbirgaran Sanat Tehran  Contract No: 3690 DOCUMENT TITLE:

 CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

 

4.9. 

Compressed Air Quality Class and Pressure at Outlet of Package:

a)  Maximum particle size:

1

µm

≤ -40

°C atm Class 2

c)  Plant air dew point:

≤ +5

°C

d)  Oil content:

1

mg/m³ Class 2

e)  Instrument air pressure:

7

bar g

at outlet of package

f)  Plant air pressure:

8

bar g

at outlet of package

 b)  Instrument air dew point:

Class 2

Page 8 of 8