Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

DOCUMENT TITLE: CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 1 of 8

BASIS DESIGN CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

01 00
REV.

13/08/2012 24/06/2012
DATE

ISSUED FOR APPROVAL ISSUED FOR APPROVAL

DESCRIPTION

H.GH H.GH.
DESIGNER

S.S.K. S.S.K.
CHECKED

M.M. M.M.
APPROVED

R.A. R.A.
P.M

Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

DOCUMENT TITLE: CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 2 of 8

TABULATION OF REVISED PAGES

PAGE Rev.00 Rev.01 Rev.02 Rev.03 Rev.04 PAGE Rev.00 Rev.01 Rev.02 Rev.03 Rev.04

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X X X X X X X X

X X X X

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

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 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
Location Elevation Latitude Longitude Iran, Sarcheshmeh 2450 m (a.s.l.) North 29.950 East 55.850
+ 35C / -25 C +32.5 C / -17.7 C 400 mm / a 564.4 mm Hg 24% @ 33 C

Climatic Conditions
Highest / Lowest Recorded Temperature Highest / Lowest Design Temperature Annual Average Rainfall Barometric Pressure Humidity of Air

Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

DOCUMENT TITLE: CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 4 of 8

3.

Design Data

3.1. Service conditions

Gas Handled Discharge Pressure Average Flow Rate (At package outlet) Plant Air (flow) Instrument air (flow) Operation Noise Limit at 1 m Cooling System Air Tank Air Quality Natural air 7.5 bar(g) 3105 Nm/hr 3050 Nm/hr @ 6 bar(g) 55 Nm/hr @ 6 bar(g) Continuous 75 dB(A) Air cooled 12000 Lit.

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

Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

DOCUMENT TITLE: CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 5 of 8

4. Calculations
4.1. 4.2.
Location: Sarcheshmeh Site Condition: -25 / +35 2450 44 C masl % Ave.

Min. / Max. Ambient Temperature: Altitude: Relative Humidity:

4.3.

Calculation of Rotary Screw Air Compressor Capacity: 3105 3050 55 20 Nm/hr Nm/hr Nm/hr % (ref. to heated type

1) Compressor Air Flow Rate: 2) Plant Air Flow Rate: 3) Instrument Air Flow Rate: 4) Desiccant air dryer losses:

air dryer without blower & -40C atmospheric dew point) 5) Altitude & Temperature effect correction factor: Air pressure at 2100 masl: Air pressure at sea level: 0.75 1.013 bar a bar a

55 Nm/hr x 1.20 = 66 Nm/hr (Desiccant air dryer capacity without correction factors) 3105 Nm/hr (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 m/hr = 78.87 m/min

Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

DOCUMENT TITLE: CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 6 of 8

78.87 m/hr x 1.15 (Over Design) = 90.7 m/min 90.7 m/hr 2 = 45.35 m/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: Dryer inlet temperature: 8 barg (Max.) 45 C c.f.1 = 1.12 c.f.2 = 0.7

C.F. = c.f.1 x c.f.2 = 1.12 x 0.7 = 0.784 66 Nm/hr 0.784 = 84.2 m/hr = 1.4 m/min

4.5.

Calculation for Refrigerant Air Dryer Sizing: 8 barg (Max.) 35 C 45 C +5 C c.f.1 = 1.06 c.f.2 = 1 c.f.2 = 1

Dryer inlet pressure: Max. Ambient temperature: Dryer inlet temperature: Dryer dew point:

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

Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

DOCUMENT TITLE: CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 7 of 8

4.6.

Calculation for Micro Filters Sizing: 8 barg C.F. = 1.1 (7 barg C.F. = 1)

Operation pressure:

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 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 m/hr 1 = 66 m/hr b) Refrigerant dryer filters: 4385 m/hr 1 = 4385 m/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 m based on providing 3 minutes supply of 3217.6 STD m/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 m 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 m based on providing 15 minutes supply of 58 STD m/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 m The buffer will be installed after air dryer.

Sarcheshmeh Converter Off Gas Handling Project

Consultant: Tadbirgaran Sanat Tehran Contract No: 3690 Document No: Rev. 01

418/250-D00-Q2-001

DOCUMENT TITLE: CALCULATION REPORT FOR COMPRESSED AIR PACKAGE

Date: 13/08/2012

Page 8 of 8

4.9.

Compressed Air Quality Class and Pressure at Outlet of Package: 1 -40 +5 1 7 8 m Class 2

a) Maximum particle size: b) Instrument air dew point: c) Plant air dew point: d) Oil content: e) Instrument air pressure: f) Plant air pressure:

C atm Class 2 C mg/m Class 2 bar g bar g at outlet of package at outlet of package