TECHNICAL SPECIFICATION

SANITARY AND PLUMBING INSTALLATION

COMPRESSED AIR SYSTEM

1. GENERAL

1.1 Description

Provide complete compressed air system to include, but not be limited to, the
following:

a. Design, preparation of shop drawings manufacture, assembly, works and site

testing, supply, delivery, off-loading, placing in final position, installation,
setting to work, commissioning and client training of a completely functional
compressed air plant including compressors, air receivers, pre-filters, Carbon
filters, desiccant type dryers or refrigerated dryers as shown, after filters, and
final filters including all necessary controls and instrumentation, individual
local control panels.

b. The supply, delivery, off loading, installation, testing and commissioning of

pipework for the complete system including compressed air, condensate and
drains, valves and all other fittings and ancillaries specified or as otherwise
required for the safe and reliable operation of the compressed air system.

c. Controls and Instrumentation including motor starters and Local Control

Panels(LCP) for items of equipment, Motor Control Centre (MCC) and Master
Control Panel (MCP) where needed, all miscellaneous instruments, Cabling,
wiring and containments including works and site testing, commissioning and
calibrating all instrumentation.

d. Drawing and documentation to fully describe the proposed installation and

fully describe the completed installation and maintenance requirements
including training of operators.

e. Provision of spare parts for plant operation.

f. Provision of training for client’s operatives.

1.2 Standards

Unless otherwise agreed by the SO/Engineer, ensure all of the Works comply with
the relevant requirements of the Standards and Codes listed below or referenced in
the body of the Specification. Alternative Standards and Codes may be proposed for
approval by the SO/Engineer, provided it can be demonstrated that the alternative
Standards and Codes comply with the requirements of the standards specified. All
Standards and Codes quoted are current version, unless specific year references are
noted.

Ensure the compressed air installation and testing, in particular comply with the
following:

a. SS CP 5 Code of Practice for Electrical Installations

b. Ministry of Manpower requirements for registration and certification of

pressure vessels

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COMPRESSED AIR SYSTEM

c. Pressure and Equipment Regulations (PER) 1999 (UK)

d. DIN ISO 7183 - Compressed air dryers specifications and testing

e. BS 1123 - Safety valves, gauges and fusible plugs for compressed air or inert
gas installations: code of practice for installation

f. BS EN 1092-1 - Flanges and their joints – Circular flanges for pipes valves
and fittings. Part 18 - Steel flanges

g. BS EN 1515-1 - Flanges and their joints – Bolting Part 1 – Selection of bolting

h. BS 5169 - Fusion welded steel air receivers

i. BS PD 5304 - Code of Practice. Safety of Machinery

j. BS 5500 - Unfired Pressure Vessels

k. BS 6244 - Code of Practice for Stationary Air Compressors

l. BS 6759 - Part 2 Specification for safety valves for compressed air or inert
gases.

2. MATERIALS

Use all new materials throughout and which are approved by the relevant controlling
Authorities and comply with the standards and codes listed.

2.1 Piping

a. Use galvanised steel pipes or stainless steel 304 or copper welded pipe as
specified from the compressors to the terminal device.

b. Provide drain pipes to BS 1387 in galvanised steel with screwed connections.

2.2 Isolating Valves

a. Ensure all isolating valves up to DN 50 for compressed air are ball-type with
screwed connections and DN 65 and above are butterfly type with flanged
connection.

b. Ensure valve seats are of PTFE or similar.

c. Provide valves to BS 5159 and to ASTM A182, grade F316L.

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COMPRESSED AIR SYSTEM

2.3 Compressor Units

a. Provide compressors complete with all necessary ancillary items to ensure

continuous automatic operation.

b. Select compressors to allow for pressure drops located downstream (filters,

vessels, dryers, pipes, valves) and for purge losses in the dryers, in additional
to the net air volume specified in this specification.

c. Ensure the specified capacity is met with discharge pressure within +5

percent and -0 percent of that specified.

d. Ensure air compressors, dryers and all auxiliary equipment are suitable for
continuous full load duty, and for the operating conditions specified on the
Design drawings.

e. Ensure compressors are designed and arranged for ease of accessibility for
maintenance and removal, without the need for major disassembly and
without disturbing the air piping or compressor alignment.

f. Provide suitable soft starting or star delta starters as shown on the Project
Specific Data Sheet for the compressor set.

g. Ensure the equipment is designed and arranged to “fail- safe” in the event of
controls or power failure.

h. Ensure all moving parts of the machine are totally enclosed or adequately
guarded.

i. Provide sealed inspection and maintenance covers, secured to the main body
by bolting.

j. Ensure equipment included in the package is suitable for the specified

operating conditions and is designed and constructed for the minimum service
life specified.

k. Ensure major parts such as casing components and bearing housings are
designed and manufactured to ensure accurate alignment on re-assembly.

l. Ensure shaft seals and bearings are accessible for inspection and
replacement with minimum disassembly.

m. Provide each compressor package with a local control panel to contain all
instrumentation and controls required for the safe and reliable control,
regulation and protection of the individual compressor and all ancillaries,
including:

i. Compressor control
ii. Motor protection and starter of star-delta or soft start type
iii. Alarms, trips and indication.

n. Provide Panels to include as a minimum the following facilities:

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COMPRESSED AIR SYSTEM

i. Door interlock: isolator

ii. Start / Stop: push-button
iii. Manual/auto: push-button
iv. Supply healthy: switch lamp
v. Controls supply healthy: lamp
vi. Compressor running: lamp
vii. compressor available lamp
viii. oil temperature high alarm lamp
ix. oil temperature low alarm lamp
x. emergency stop operated lamp
xi. air filter d.p. high alarm lamp
xii. oil filter d.p. high alarm lamp
xiii. Interface Terminals and logic for the MCP inputs and outputs
xiv. Analogue or Digital indicators for:
• air delivery temperature
• air delivery pressure
• total running hours
• total loaded hours
• Compressor Units

o. Provide compressor units of the type specified in the Design drawings,

suitable to safely withstand specified pressures, temperatures and other
service conditions.

p. Ensure the design permits ease of safe operation and maintenance of the
compressor unit, whilst minimizing the risk of physical injury.

q. Ensure that compressor unit components in excess of 25kg are fitted with
suitable devices to attach them to lifting gear

2.4 Wet Air Receivers

a. Ensure all air receivers are constructed to BS 5169, or ASME 10 or

equivalent. Ensure a one millimetre corrosion allowance is incorporated
by the Manufacturer.

b. Ensure the receiver is marked with Safe Working Pressure,

Manufacturer’s nameplate and test authority stamp/plate.

c. Provide a hinged access manhole minimum of 600 mm diameter in the

vessels.

d. Provide flanged branches suitably sized for system pipeline sizes for inlet
and outlet.

e. Provide connections for drain, pressure gauge and pressure sensors.

f. Fit safety valves, 100 mm dial pressure gauge with siphon and cock and
an automatic drain valve to vessels. Pass drain lines through an
interceptor before discharging to drain.

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COMPRESSED AIR SYSTEM

g. Ensure the interiors of vessels are painted with corrosion resistance paint.
Paint the vessels externally to the manufacturers standard specification.
Provide vessels with lifting lugs and pressure relief valves.

h. Provide air receivers with a total cubic capacity as detailed on the Design
drawings.

i. Ensure vessels are constructed of carbon steel to BS1501-151, Grade

430A or similar equivalent.

2.5 Dryers

a. Provide dryers as complete packaged, enclosed assemblies mounted on

fabricated steel base-plates suitable for direct mounting on to concrete
plinths.

b. Mount a pre-filter and after filter on the same base-plate. Provide an

outlet air silencer for each dryer.

c. Ensure that the volume of purge air is minimised

d. Ensure dryers are complete with all ancillary items necessary for
continuous automatic operation unattended with one vessel or modular
cells drying while the other vessel or cells regenerates.

e. Ensure the equipment is designed and arranged for ease of accessibility

for maintenance and removal, without the need for major disassembly.

f. Ensure that all hot surfaces are thermally insulated for personnel
protection to limit surface temperatures to 40°C.

g. Ensure the equipment is designed and arranged to “fail-safe” in the event

of controls or power failures.

h. Provide each dryer with an integral local control panel including dew point
detector indicator for faults, generating (in service), drying/regenerating,
temperature, dew point and moisture. Control the cycle of
drying/regeneration to maximise the capacity of the desiccant.

i. Provide all instrumentation and controls required for the safe and reliable
control, regulation and protection of the individual dryer and ancillaries.

2.6 Filters

a. Provide air filtration before the dryer to the performance requirements

specified on the design drawings.

b. Ensure each air filter is complete with integral differential pressure

indicator and automatic water trap be piped and collected locally.

c. Provide an air filter after the dryer to remove particle carry-over, in

accordance with the performance requirements specified on the design

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COMPRESSED AIR SYSTEM

drawings and complete with bypass integral differential pressure

indicator.

2.7 Drain Trap Assemblies

a. Fit drain trap assemblies at the base of each vertical branch main,
moisture separators and at air receivers and comprise isolating valve,
strainer, compressed air trap and liquid discharge pipe extended to the
nearest gulley.

b. Fit a pressure balance pipe between the branch main, separator inlet or
air receiver where shown to be required

2.8 Pressure Reducing Sets

a. Provide pressure reducing sets with; a moisture separator, trapped drain,

stop valve, strainer with blow-down provision, inlet pressure gauge,
pressure reducing valve, stop valve, and safety relief valve with drain at
low level.

b. Provide an outlet pressure gauge within one metre of the downstream

connection of the by-pass pipe.

c. Ensure the complete assembly has a full-bore by-pass with globe valve.

d. Ensure the pressure reducing valve is supplied with filtered compressed

air for operation, through a regulator.

e. Install a valve pressure control pipe between the pressure reducing valve
and the low pressure side, close to the pressure gauge

3. ASSOCIATED WORKS

3.1 Controls & Instrumentation

3.1.1 General

Ensure the compressed air system controls are fully automatic and capable of
running unattended.

Ensure the Controls and Instrumentation and Electrical work include but are not
limited to the following:

a. A Control Panel for the compressed air system.

b. Instrumentation mounted on the compressed air system.

c. A Sequence (Pressure) Controller provided by Compressor Manufacturer.

d. A complete controls cabling installation for each Compressor and Dryer.

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COMPRESSED AIR SYSTEM

e. A complete power cabling installation for all electrical equipment between.

f. Ensure that the MCP as a minimum includes the following items

i. Isolator
ii. Compressor lead/lag selection switch/indicator
iii. Plant is available to run lamp
iv. supply healthy lamp
v. controls supply healthy lamp
vi. Compressor running lamp
vii. Compressor available lamp
viii. Compressors common fault lamp
ix. Each dryers running lamp
x. Dryer fault l amp
xi. Air filters differential pressure alarm lamp

g. Analogue or Digital indicators for:

i. Header air delivery temperature
ii. Header air delivery pressure
iii. Header air delivery pressure dew point or moisture contents

Provide the following signals to the BMS wired out to terminals:

a. Each Compressor:
i. Running
ii. Stopped
iii. Fault
iv. Discharge Pressure

b. Each Dryer : Fault

c. System: Supply Pressure

Ensure the Control Panels include facilities for the following input and output
signals:

a. Outputs:
i. Running
ii. Stopped
iii. Fault
iv. Discharge Pressure

b. Inputs:
i. Start
ii. Stop

3.1.2 Air Filters

Monitor each air filter for dirty condition by a differential pressure switch. Ensure
that, on reaching the set point, an alarm will be raised at the Control Panel.

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COMPRESSED AIR SYSTEM

3.2 Electrical Works

Include the following in the Electrical Works associated with this system:

a. A Motor Control Centre for the system containing motor starters for all
drive motors on the system except those on packaged equipment having
motor starters provided in the Control Panel (CP) and moulded case
circuit breaker protected feeds to all CPs

b. Power cabling and containment between the MCC and all motors/CPs.

c. An earthing installation for the electrical system described above

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