Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public.

इंटरनेट मानक

“!ान $ एक न' भारत का +नम-ण”Satyanarayan Gangaram Pitroda

“Invent a New India Using Knowledge”

“प0रा1 को छोड न' 5 तरफ”Jawaharlal Nehru

“Step Out From the Old to the New”

“जान1 का अ+धकार, जी1 का अ+धकार”Mazdoor Kisan Shakti Sangathan

“The Right to Information, The Right to Live”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता है”Bhartṛhari—Nītiśatakam

“Knowledge is such a treasure which cannot be stolen”

“Invent a New India Using Knowledge”

है”ह”ह

IS 15879 (2009): Breathing air compressor package [MED 22:Compressor, Blowers and Exhausters]

IS 15879 : 2009

Jun e 2009

Indian Standard

BREATHING AIRCOMPRESSORPACKAGE - SPECIFICATION

ICS 13.340.30; 23.40

c BIS 2009

BUREAU OF INDIAN STANDARDSMANAK BHAVAN , 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

Price Group 6

Compressor" Blo« ers and Exhausters Sectional Corumitree. !\1r. D ~ ~

FOREWORD

This India n Stan da rd was adopted by the Bureau of Indian Stan dard s, afte r the draft finali zed by theCompressors, Blowers and Exhausters Sectional Committee had been approved by the Mechanical Enginee ringDivisio n Council.

Breathing air co mpressor packages are widely used by Fire Services, Police Search Units, Hazardous MaterialHandl ing Organiza tions. Disaster Management Authorities and divers etc. This standard has bee n formul atedto assist manufacturers. purch aser s and users as a common guide for performance eva luation and rating ofbreathing air compresso r package. This standard also provides the requirements of ai r qua lity for compressedair. which is based on BS EN 12021 .Respiratory protecti ve devices - Compressed air for breathing apparatu s' .Biological effects of res pirato ry hazar ds on acco unt of presence of pat hog ens in the air are not take n intoaccount.

The user of th is standard should note that different requirements may be needed for differ ent applicat ions ofbreather air and aj ud icio us decision should be taken for the end use of breat hing ai r. The term ' breathing air'in itself does not relate to a specific leve i of contam inant removal. The definition ofa contaminant depends onthe application as well. Because of this. compressed ai r require ments in various industr ies and laboratorieswill vary significant ly. The purification method needed for any part icular application will depend on thespecific requ irements for that application. As a result. it is crit ical for co mpresse d ai r users to be aware o fpotent ial contam inant s in their sys tems, the effec ts of these co ntami nants , and potent ial remed ies forsuccessful contamination control. Typical contaminants in compressed air are given in Annex A for information.

The compressed breath ing air is stored at a high pressure in high pressure cy linde rs/rece ivers and thereforethe operators of compressors and users of cylinders should note that cy linde r designed to re levan t Ind ianStandard are to opera te safe ly, if used in acco rdance with spec ified se rvice condi t ions for a specified finit eservice life on ly. It is the respons ibility of the owners and users of th is standard to ensure that cy linders areper iod ically tested as per norms laid down in Gas Cylinder Rilles, 2004, as amended from tim e to time and asenforced hy the regulat or. Other applicable statutory requ irement s as enforced from time to tim e are also to becomp lied with.

The composition ofthe Commi ttee responsible for the formulatio n of the standa rd is give n in Annex C.

For the purpose of deciding whether a part icular requ irement of th is standard is co mplied with, the final va lue,observed or calculated. exp ressing the result of a test or analysis. sha ll be rounded off in accordance withIS ~ : 1960 ' Rules for rounding off numer ical values (revisedi' , Th e number of s ignificant places reta ined inthe rounded off value should be the same as that of the speci fied value in thi s standard.

IS 15879 : 2009

Indian Standard

BREATHING AIR COMPRESSORPACKAGE - SPECIFICATION

2 REFERENCES

I SCOPE

1.3 This standard does not deal with:

a) compressed air used for medical purposes, and

b) compressed air used for industrialapplications.

The following standards contain provisions, whichthrough reference in this text, constitute provisionsof this standard. At the time of publication, theeditions indicated were valid . All standards aresubject to revision and parties to agreements basedon this standard are encouraged to investigate thepossibility of applying the most recent editions ofthe standards indicated below:

IS No.

7494: 1981

10431: 1994

3.4 Packapd Compressor - Skid mounted breathingair compressor package complete with high pressurecompressor, its driver, air intake andfiltration system,inter stage coolers and after-cooler, air purificationsystem, condensate removal system, pressure safetyvalves, instrumentation and controls and otherassociated auxiliaries, that are specified andcompletely assembled and tested by themanufacturer, requiring only electrical power supplylfuel supply by purchaser to operate.

3.5 Worklag Prasare - The operating pressureat which the compressor has to compressatmospheric air.

3.6 CharglD& Rate - The rate offilling a specified

For the purpose of this standard the following termsand definition shall apply.

3.1 Supplier - The partysupplying the machines.Thesupplier mayor may not be the actual manufacturerofthe machines. The term 'supplier' shall also coverany party with whom the supplier places an order forpartial compliance.

3.2 Purchaser - The party purchasing the machines.The term 'purchaser' shall also cover person orpersons authorized in writing by the purchaser toact on his behalf for inspection of the machines.

3.3 Manufacturer - For the purpose oflhis standard,the manufacturer is the company or organization,which manufactures the compressor and evidencesits responsibility by affixing its name or its registeredtrade-mark or trade name and its address, to theunit.

ISlIS02151 :2004

Titlelessthan 1 100MPa(112kgf7mm2

)

(third revision)

Specification for steel for valvesfor internal combustion engines(first revision)

Measurement of air flow ofcompressors and exhausters bynozzles (first revision)

Acoustics - Noise test code forcompressors and vacuum pumps- Engineering method (Grade 2)

3 TERMINOLOGY AND DEFINITIONS

Title

Three-phase induction motors(fifth revision)

Single-phase small ac anduniversal electrical motor(second revision)

Degrees of protection providedby enclosure for rotatingelectrical machinery (firstrevision)

Stainless steel bars and flats ­Specification (first revision)

Stainless steel plate, sheet andstrip (first revision)

Refillable seamless steel gascylinders - SpecificationNormalized steel cylinders (thirdrevision)Quench and tempered steelcylinders with tensile strength

(Part I) : 2004

(Part 2) : 2004

7285

6911: 1992

6603:2001

4691: 1985

IS No.

325 : 1996

996: 1979

1.1 This standard specifies requirements, design,materials, fabrication, inspection, testing andpreparation for shipment of the breathing aircompressor packages used for supply of highpressure breathing air and filling of compressed aircylinders. The standard covers compressors ofmaximum working pressure 41.4 MPa (g) or less.

1.2 This standard also specifies the minimumacceptable limits of constituents in breathing air andmaximumallowablecontaminationconcentration in it.

(l)

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IS 15879: 2009

volume (that is a cylinder or air receiver) from zeropressure to the specified working pressure.

3.7 System Capacity - Sizing of the package interms of capacity (that is now) to supply thebreathing air at specified charging rate. Systemcapacity shall be in ' Iitres per min (lpm)' or 'StandardCubic Metre per hour (SmJIh).

NOTE - An add itional 10 percent margin over theminimum air requirement may be provided 10 coverleakagc losses at brcathing air stations .

4 BREA11IING AIR QUALITY REQUIREMENTS

The quality ofbreathing air is of utmost importance,as being life support system. Contaminationsexceeding the prescribed limits can be hazardous. Inabsence ofmore stringent national requirements, theacceptable level quality for breathing air, consideringboth physiological and engineering safety aspectsshall be as specified in Table I .

5 DESIGN

5.1 Geaeral

5.1.1 The breathing air compressor package shallbe designed to deliver high pressure air ranging from20 MPa (g) to 41.4 MPa (g) or less that meets therequirements of respiratory quality air as specifiedin Table I .

The purchaser may also specify the quality ofbreathing air required, depending upon theapplication. However, in any case, the quality ofbreathing air shall not be inferior to the acceptablelimits specified in Table I . The method ofmeasurements shall be as agreed to between thepurchaser and the manufacturer/supplier.

5.1.2 The compressor and its purification system

shall be designed for 110 percent of maximumdischarge pressure or pressure relief valve setpressure, whichever is higher.

5.1.3 All high-pressure air piping/tubing shall berated for 110 percent of maximum working pressureand utilize seamless stainless steel tubing. All high­pressure air piping/tub ing connections shall usecompression fit design fittings . All piping and tubingshall be properly supported and protected to preventdamage from vibration during shipment, operation,or maintenance. Piping and tubing shall be installedin a neat and orderly arrangement, adapting to thecontours of the system. All instrument tubing shallbe 300 series stainless steel conforming to IS 6911 orequivalent standard.

5.1.4 The compressor package shall be equippedwith a dry type inlet filter cum silencer that is, suctionmuffler, with replaceable elements. Inlet filter shallprevent entry of particles larger than 2 microns with99 percent + dirt removal efficiency. Ahigh differentialpressure indicator across inlet filter shall be providedon the instrument panel, which shall indicatemaintenance status for the inlet filter. Alternatively,a maintenance status indicator for the inlet filter shallbe provided locally or on the panel.

5.1.5 The package shall be designed such that alloperating controls and related indicators are locatedon a panel, at the front of the package allowing' in­situ' (on-site) monitoring and control.

5.1.6 The package shall be 'containerized' usingfabricated steel structures and panels. All structurefasteners shall be concealed and all access panelsshall include hinges and latches.

The cabinet/container shall incorporate lift-off

Table 1 Breathing Air Quality

[Clauses 4, 5.1.1, 5.2.3, 5.3.2 and 9.2(g)]

51 No.

(I)

Co.po.e.tslCollta.la..tI

(2)

Sy.bol

(3)

Allowable CoaceatntloD/Coateat

(4)

21:l::I percent

Shall not exceed IS mUm' (IS ppm)

Shall not exceed SOO mUm' (SOO ppm)

No free liquid water"

2S ppm at package outlet for filling cylinders

SO ppm at cylinder outlet (cylinder pressure 4 MPato 20 MPa (g)

3S ppm It cylinder outlet (cylinder pressure >20 MPa (g)

Shall not exceed O.S mgtm'

0,CO

CO,

H,O

<n)'lCft CClnmltralion by volume (dry air)

Carbon monoxide

e.tIon dioxide

Water vapour

v) Oil c:ornponats(Condensed hydrocatbons)

vi) <>dow. tIawor substances IIld tmte Free of any significant odour or taste

NOTE - ~ conditions of 1ISIIIC and storage of compmsed air supply is not known the pressure dew point shill notexceed - 11°C. •

II Rcfcmd to 0.101 3 MPa. 200(' -S without free liquid water.

i)

ii)

iii)

i.)

2

panels or its equivalent, for access of the internalcomponents for inspection and maintenance. Thecabinet/container shall bedesigned to minimize noiseemission and shall include noise attenuatinginsulation.

In case of air cooled compressor configuration, thecabinet/container design shall permit flow of ambientair with desired volumetric flow which can removethe heat of compression from the compressor. Thecool ing system shall also include a dischargeextractor to completely vent the resulting hot air outof the cabinet to a safe area.

In case of water cooled compressor configuration,the cabinet/container design shall permit installationof heat exchangers for removal of heat and shall berequiring only one interface connection for coolingwater supply and return.

5.1.7 If required by the purchaser, breathing aircompressor package shall be mounted on anti­vibration mounts, which shall be provided by thesupplier.

5.1.8 Unless otherwise spec ified , installation shallnot require a special foundat ion; however it is theresponsibility of the purchaser to ensure that theinstallation site has a solid and level foundation thatcan support the weight of the system , the availabilityof a qualified source of air for the intake of thecompressor and adequate ventilation.

5.1.9 The inlet to the compressor should be solocated so as to minimize the possibilities ofhazardous substances being drawn into the system.

5.1.10 Noise Level

The noise level with sound attenuating treatmentshall be limited to:

a) Not more than 85 dB at one metre distance forportable or mobile packages, and

b) Not more than 80 dB at I m distance forstationary packages.

The temperature of breathing air supplied for useshall not exceed 35°C at any time to ensure operatingpersonnel comfort.

5.2 Compressor

5.2.1 The compressor shall be a three or four stage,three to four cylinders, single acting, andreciprocating type; designed for continuous duty atspecified working pressure with the specifiedcharging rate .

5.2.2 Unless otherwise specified, compressor shallbe ofair cooled type. Water cooled type compressormay be selected based on mutual agreement between

3

IS 15879 : 2009

the purchaser and the supplier.

5.2.3 The compressor may be either oil free type oroil lubricated type . If an oil lubr icated compressor isspecified. the discharge air shall meet the oil carryoverlimits specified in Table I and shall also have a highdischarge temperature alarm or carbon monoxide (CO)alarm , or both.

5.2.4 Material of Construction

Materials of construction for critical components ofcompressor shall be as per manufacturer's standardand design except for the following:

a) Crankcase including cylinders and heads shallbe ofcast iron or cast steel or aluminium alloy.Cylinder liners shall be of alloy steelconforming to steel designation 12Cr13 ofIS 6603 or equivalent standard specified bythe manufacturer;

b) The crankshaft shall be of forged steel, singlepiece construction and shall be supported inthe crankcase by adequate number ofbearings;

c) The connecting rods shall be of alloy steelconforming to steel designation 12Cr 13 ofIS 6603 or equivalent standard specified bythe manufacturer and shall incorporate a rollerbearing at the crank end and needle bearing atthe pin end;

d) The pistons shall be constructed of heavyduty aluminum alloy or stainless steelconforming to IS 6911 or equivalent standardspecified by the manufacturer;

e) Piston rings shall be suitable for the intendedservice. Piston rings of oil free compressorsshall be of polymeric compound. Piston ringson oil lubricated machine can be of cast iron.The purchaser may specify the minimumservice life of piston rings;

f) Valves shall be ofsteel conforming to IS 7494or equivalent standard specified by themanufacturer; and

g) The compressor's flywheel shall be of castiron. Incase of 'aircooled' compressor, a multi­wing, high velocity cooling fanshall be integralto the flywheel.

5.2.5 Cylinders

The cylinders shall be equipped with deep coolingfins on the external surface for optimum heatdissipation. The cylinders shall be arranged in a 'Vor 'W' or 'X' configuration. For an air cooledmachine, each cylinder shall be located directly in

IS 15879 : 2009

the forced draft provided by cooling fan. Thecylinders shall be removable from the crankcase.

5.2.6 Valves

Compressor valves shall be designed specially forsevere conditions, which appear in high-pressure aircompressors. Valve lift, spring characteristics andthe material of the plates shall be chosen accordingto the operating conditions.

Unless otherwise specified, velocity of the airflowshould DOt exceed 60 mls for intake valvesand 40 m/sfor outlet valves.

5.1.7 For high pressure air compressors, requiringlubricated or mini-lubricated cylinders, to preventauto-ignition, predicted maximum actual dischargetemperature limitshall bemuch lower than 130°C andthe same shall be subject to purchaser's approval.

5.1.7 .1 The supplier/vendor shall ensure that therecommended cylinder lubricating oil is suitable fromthe point ofview ofauto-ignition that can occur withapplications handling air at high pressures. Syntheticoil can be offered only with specific approval of thepurchaser.

5.2.8 Lubrication

a) The compressor shall 6e lubricated by acombination of splash and low pressurelubrication system. If required , the final stageof compression shall be lubricated by apressurized lubrication circuit. The otherstages and the driving gear shall be splashlubricated.

b) Type and quality of lubricant recommended'by the manufacturer shall only be used.

c) The pressure lubrication circuit shall includea positive displacement oil pump, gear drivenby the crankshaft, and a non-adjustable oilpressure regulator. A replaceable cartridgetype filter element shall also be provided. Ahighly visible sight glass/level gauge shall beprovided to check the level of lube oil. The oildrain for the compressor shall be piped to theoutside of the frame for easy access.

5.1.9 Inter- and After-Coolers and Oil Cooler

a) Unless otherwise specified by the purchaser,all inter-coolers and after-coolers shall be of'Air cooled' type and shall be as permanufacturer's standard.

b) Unless otherwise specified by the purchaseroil cooler shall be of ' Air cooled' type andshall be as per manufacturer's standard.

4

c) An inter-cooler shall be provided after eachstage ofcompress ion and an after-cooler shallbe provided after the final stage ofcompression. The coolers shall be individuallydetachable from the compressor. In case of 'aircooled compressor' the same shall be locateddirectly in the air flow path of cool ing fan.

d) The air cooled after-cooler shall be designedto cool the discharge air to within 14°C ofambient air.

e) Unless otherwise specified by the purchaser,all coolers shall be fabricated from series 300stainless steel conforming to IS 6911.Alternate materials, such as copper or copper­nickel alloy, suitable for the environment inwhich the compressors are being installed maybe used, if agreed by the purchaser.

f) Oil and air cooling after each stage may alsobe achieved either through multiple rows ofcopper-nickel and/or steel finned tubes,arranged in a compact radiator block orthrough stacked shell and tube type heatexchangers (liquid cooled), and attacheddirectly to the compressor package.

5.1.10 Separators

a) Unless otherwise specified by the purchaser,a separator shall be installed after each stageof compression. A coalescing type separatorshall be supplied at the discharge of thecompressor.

b) Unless otherwise specified by the purchaser,manual drain valves for manual draining shallbe provided for all separators.

c) If specified, an automatic condensate dra insystem, by means of diaphragm valvesactuated by a timer-controlled solenoid, shallbe provided for all separators . Adjustable draintimers shall be factory preset to drain theseparators approximately every 15 min forapproximately 6 s. Manually operated valvesshall be supplied to override the automaticoperation of the automatic condensate drainsystem for test and maintenance procedures.

d) On unloading ofthe compressor on shutdown,condensate shall be drained so thatcompressor is ready for an unloaded restart.

e) Ifspecified, condensate and escaping air shallbe led from the separators into a condensate­receiving tank. The unit shall be fully piped ,with high-strength flexible hoses forconnection on the suction and discharge side.

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IN

5.3 Air Purification System

5.3.1 Compressed breathing air systems shall besupplemented with a purifier to remove commoncontaminants from compressed breathing air. Apurification system shall be designed to:

a) filter out oil, liquid, water and solids;

b) reduce water vapour content;

c) convert carbon monoxide to carbon dioxide;and

d) filter out undesirable taste and odour.

5.3.2 The purification system shall be capable topurify high pressure air into a high quality air thatmeets or exceeds the requirements specified inTable I.

5.3.3 Purification shall be achieved by a mechanicalseparation of condensed oil and water droplets,absorption of vaporous water by a desiccant,absorpt ion of oil vapour and elimination of noxiousodours by activated carbon and conversion ofcarbonmonoxide to respirable levels of carbon dioxide bycatalyst.

5.3.4 The high pressure purification chambers shallhave a working pressure of equivalent to relief valveset pressure. The purification system shall utilizereplaceable cartridges. The purification system shallbe designed to allow the replacement of cartridgeswithout disconnecting the systems piping. Thedesign ofthe chambers shall preclude the possibilityof operating the system without cartridges installedor with improperly installed cartridges. A bleed valveshall be provided to allow venting of the purificationsystem prior to installing cartridges. A pressuremaintaining valve and check valve shall be suppliedto downstream of the purification system to increasethe efficiency of the purification system bymaintaining a positive back pressure. A check valveshall be supplied between the coalescing separatoron the compressor discharge line and the purificationsystem to maintain the positive pressure in thepurification system when the compressor shutsdown.

5.3.5 The purification shall include a moisturemonitoring system. The sensor shall be located inthe purifier cartridge for direct monitoring ofmoisturelevels . A display module, to indicate status of thecartridge shaIl be supplied in the instrument panel.The moisture monitoring system shall be of a fail­safe design. Should electrical contact between thedisplay module and sensor be disconnected. animmediate shut down shall be initiated. For theabsolute safety and the highest quality breathingair, no manual override shall be supplied for themoisture monitor.

IS 1S879 : 2009

5.3.6 If specified. in order to meet the dew pointtemperature requirement, suitable and appropriate airdryers shall be provided.

5.4 8rt.thinC Air StoraCf

5.4.1 HP Air Cylinders

Air storage system shall include breathing air storagecylinders/vessels consisting of two or four seamlesscylinders/vessels , manufactured according to IS 7285(Part I) or IS 7285 (Part 2) and approved by theStatutory Authority. Any other type of seamlesscylinders approved by Statutory Authority may alsobe used. These cylinders can either be mounted in avertical or horizontal configuration in a rack. The rackshall be designed to support the receivers in a securemanner and permit visual inspection ofthe receiver'sexternal surface. Applicable statutory requirementsfor cylinders and its fittings shall becomplied with.

5.4.2 HP Air Receivers

Air storage system shall include breathing airconsisting of high pressure air receiversmanufactured according to IS 7285 (Part I) or IS 7285(Part 2) and approved by the Statutory Authority.Any other type of seamless cylinders approved byStatutory Authority may also be used. Air receiverts)shall be mounted in close proximity to the compressorpackage. Applicable statutory requirements forcylinders and its fittings shall be complied with.

Sufficient air storage capacity shall be provided tosupply the air requirements (that is for a specifiedset of conditions and for a specified period of time)following a total loss of power to the compressor.

5.5 Pressure Reduclnc Station and Manifold

The breathing air manifold shall beprovided, whichshall be the termination point for the breathing airsupply piping. A pressure reducing station shall alsobe installed in the discharge header which shallassure that air pressure to the respirator(s) does notexceed apreset limit Pressure at the inletto the bre8dlingair lines should be no higher than 0.86 MPa (g).

As a minimum, manifold and pressure reducingstation shall include:

a) A filter rated to remove 99.999 98 percent ofallliquid and solid particles of 0.03 microns orlarger. The filter shall bedrainable for removalof trapped fluids.

b) Pressure regulator with 0 to 0.86 MPa (g) rangeand a gauge with a scale of 0 to 1.4 MPa (8).The pressure regulator shall be installeddownstream from the filter.

c) Bypass piping around the pressure reducing

IS 15879 : 2009

valve (PRV) with a globe valve for manualpressure regulation and a safety relief valve(SRV) installed downstream ofthe PRYbypasspiping.

d) Quick-disconnect check units for the air hoseconnection.

6 ACCESSORIES

6.1 Prime Mover

6.1.1 Unless otherwise specified, prime mover shallbe electrical motor. Engine as a driver can be used, ifspecified by the purchaser.

6.1.2 The rated power of the driver shall be at least10 percent higher than the maximum power requiredby the compressor under any operating condition .

6.1.3 As specified, engines can either be dieselengine or gasoline engine, complete with air intakesystem, fuel system, lubrication system, etc. In sucha case, care shall be taken to ensure that exhaustgases from a combustion engine powered compressoror from other nearby sources may not contaminatethe air drawn into the system.

6.2 Drive Arrangement

Power from the driver shall be transmitted to thecompressor through V-belt design or direct drive(through rigid coupling or universal shaft coupling) .The V-belt drive shall allow tightening of the beltsautomatically.

6.3 Guards for Moving Parts

Non-sparking guards shall be provided for all movingparts.

6.4 Nameplate and Rotation Arrow

6.4.1 A nameplate shall be securely attached at areadily visible location on the equipment and on anyother major piece of auxiliary equipment. Thenameplate shall indicate operating and designparameters as per the manufacturer 's standardpractice.

6.4.2 Rotation arrows shall be affixed at a prominentplace on the compressor.

6.5 Optional Items

Optional items of the breathing air compressorpackage are given in Annex B.

7 ELECTRICAL

7.1 The electric motor shall be single-phase or three­phase suitable for 240/415 V respectively and 50 Hzcurrent Electricalmotor shall beas per IS996 or IS 325or equivalent standard. The purchaser shall spec ifythe enclosure type and degree of protection based

6

on area ofclassification and intended use of package .

7.2 The motor control center shall include an direct­on-line (DOL) magnetic motor starter, fusedtransformer and programmable logic controller (PLC)controller. The electrical panel installed shall be builtin compliance to internat ional electrical standardsand shall be affixed with an applicable certificationlabel.

8 INSTRUMENTATION AND CONTROL SYSTEM

8.1 Instrument Panel

a) An instrument panel shall be installed on thefront of the system. The instrument panel shallinclude, at minimum, a pressure gauge for eachstage of compression, a pressure gauge forcompressor oil pressure, OFF /ON selectorswitch, inlet filter maintenance indicator,power-on light, moisture display module, andfault lights .

b) The instrument panel shall be located andarranged for visib ility and easy access by theoperator and for the accessibi Iity forinspection and maintenance. All componentsinstalled in the instrument panel shall besecurely supported to eliminate vibration andundue force on piping and to prevent damageduring shipment, storage, operation andmaintenance.

c) All instrument panel mounted gauges shall beof63 mm to 100mm diameter. Pressure gaugesshall be liqu id filled. Each panel mountedcomponent shall be labelled with an engravednameplate.

8.2 If specified by the purchaser, the compressorcontrol may consist of a programmable logiccontroller (PLC) for monitoring, protection andcontrol of standard compressor systems.

8.3 Instrumentation and Controls may include someor all ofthe following :

a) An IP56 enclosure as per IS 4691;

b) Audio-visual alarms comprising of Annun-ciator and 24 V Hooter ;

c) On/OfT selector switch or push-buttons;

d) Emergency stop push-button;

e) Warning and alarm indicator lights:

I) All lamps shall be as a LED cluster type;

2) Lamp test function (Built-in); and

3) Lamps to flash representing alarmcondition.

t) Warning and alarm functions ;

g) Driver overload alarm;

h) Required engine controls (including constantspeed control through head un loaders orgovernors);

J) Hour Meter - A non-resettable hour metershall be supplied to record the number ofoperating hours. The hour meter shall beinstalled on the instrument panel;

k) Pressure Switch and Gauge - Thecompressor oil pressure shall be monitored bya pressure switch and pressure gauge installedin the instrument panel. The compressor shallshut down and a fault light shall illuminate, incase of drop in oil pressure below presetvalues. The oil pressure switch shall be by­passed during start-up to permit the oil pumpto achieve normal operating pressures ;

m) Temperature Transmitter - A temperatureelement with temperature transmitter shall besupplied on the discharge line ofthe final stageof compression. The compressor shall shutdown, generate an audible alarm and a faultlight shall illuminate should be final stage ofdischarge temperature exceed the set pointduring operations;

n) Shut-Down Switches - For ease of systemdiagnosis and maintenance , the low oilpressure and high pressure air shut-downswitches shall be equipped with suitableconnectors;

p) Annunciators - All fault lights shall beinstalled on the instrument panel and shall beLED cluster type and red in color or itsequivalent. Each fault light shall be labelledwith an engraved nameplate;

q) CO Monitor and Calibration Kit -Ifspecified by the purchaser, CO monitor andcalibration kit shall be provided along with itsalarm functions; and

r) Online Dew Point Meter - If specified by thepurchaser, an online dew point meter shall beprovided on the panel.

9 INSPECTION ANDTESfING

9.1 General

Material composition and physical propertycertificates for material ofconstruction shall be madeavailable to purchaser or his authorizedrepresentative upon request. Pressure containingparts shall not be painted until the specified

7

IS 15879: 2009

hydrostatic test is carried out.

9.2 Followinginspectionand tests shall be carried out:

a) Hydrostatic test for all cylinders and pressurevessels. Duration of hydrostatic test shall beas per applicable code;

b) Air leak test of complete unit at specifiedmaximum design pressure;

c) Mechanical running test for 4 h;

d) System capacity and discharge rate shall bedemonstrated either by receiver fil1ing methodor by restriction orifice as per IS 10431.Duration of test shall be minimum I h oncontinuous running;

e) Functional test of control panel and checkingof all safety systems and controls;

t) Safety relief valves shal1 be tested for theiroperation and corresponding feedback to thecontrol panel ;

g) The compressed air shall be tested forrequirements specified in Table I . This testmay be carried out at approved laboratories;and

h) Noise level test shall be carried out inaccordance with IS/ISO 2151 :2004 forrequirements specified in 5.1.10.

10 PREPARATIONFORSHIPMENT

10.1 The entire system shall be tested by thesupplier/packager prior to shipment. Compressormanufacturer 's test report and supplier's test reportshall accompany the system at shipment.

10.2 Supplier's nameplate shall be securely affixedto the electrical box. The nameplate shall include,manufacturer's name, model number, serial number,compressor block number, system operating pressure,compressor operating speed, capacity and chargingrate, driver rating (that is kW), voltage, frequency,amperage and date of manufacture.

10.3 The system shall be prepared for motor freighttransport, bolted to a wooden pal1et, wrapped in clearplastic, and fully protected by heavy reinforcedcardboard. Component parts, loose parts orassociated parts shal1 be packaged separately andshipped on the same pal1et, iffeasible.

10.4 The equipment/package shall be suitablypacked, fastened to avoid damage during transit andcrated for shipment and storage for a period of sixmonths. Lifting, unpacking and handling instructionsshall be securely attached to the exterior ofthe largestpacking in a well marked weather proof container.

IS 15879 : 2009

The upright position of lifting points , gros s weightsand dimensions be clearly marked on each package.Each package shall clearly identify the equ ipmentcontained therein.

11 VENDOR'S DATA

11.1 Proposals

The vendor's proposals shall as a minimum includethe following:

a) Manufacturer's standard data sheets;

b) Schematic diagram for the package/piping andinstrumentation drawing;

c) General arrangement draw ing;

d) List of recommended commissioning spares;

e) List of vendor's standard spare parts for twoyears normal operation;

f) List of standard tools;

g) Any start-up, shutdown or operatingrestrictions required to protect the integrityof the equipment/package; and

h) Manufacturer's catalogue/leaflet.

11.2 Contrad Data

11.2.1 The supplier shall furnish the following vendordata/drawings for purchaser's review/approval, afterplacement oforder:

a) Manufacturer's standard data sheets forcompressor, prime mover, electrical system ,instrumentation and controls, etc ;

b) Schematic diagram for the package/Piping andinstrumentation drawings;

c) General arrangement draw ings ;

d) Foundation drawings;

e) Cross section drawings with bill of material ofeach equipment formin g part of the package;

f) List of spare parts that is commissioningspares , spare parts for two years normaloperation, standard tool s, etc ; and

g) Installation , operation and maintenancemanual. Manual shall also give completedetails regarding safety precautions, checkingof safety devices and mandatory retest ing ofequipments /vessels as per stipulatedfrequency.

11.2.2 All transmittal documents (covers), drawingsand data shall have a title block (in addition tovendor's standard title block) which shall at leastcontain the following contract information:

a) Purchaser's and consultant's corporate name ;

b) Project name ;

c) Client/Customer 's name ;

d) Equipment name and item No .; and

e) Purchase order No .lPurchase specification.

11.2.3 All vendor data/drawings/documents shall bein SI/metric systems.

11.2.4 Two sets of Final /As Built drawings anddocuments shall also be submitted.

ANNEX A(Foreword)

COMMON COMPRESSED AIR CONTAMINANTS

A-I Atmospheric air is composed of countlesscontaminants consisting of unwanted gases, liquiddroplets, and particles. Air is the universal diffuser,as water is the universal solvent. Essentially all gases,vapours and aerosols small enough to be suspendedenter the atmosphere eventually. The atmospheretransports the entrained components, quite oftenover long distances, until they return to the earth'secosystem.

8

Air is composed of a multitude of gases , vapoursand aerosols that all vary in concentration ,depending on time , location of nearby sources, etc.In addition, the definition of a contaminant dependson the application ofair. Airborne pollen, for example,is a boon to vegetation (and is certainly not acontaminant) as it is transported from one locationto another, but it may be harmful to animals or humanswith respiratory ailments. Similarly, water vapor in

the air we breathe is essential to keep the mucousglands moist, but it also breeds harmful microbesand contributes to metal corrosion.

General contaminants ofbreathing/respiratory air areas under :

a) Carbon Monoxide (CO) - Carbon monoxideis the most toxic contaminant in compressedair. It enters the breathing air system throughthe air intake, or is produced by overheatingof piston type compressors. The air intakemust be placed away from engine exhaust orother sources of carbon monoxide.

b) WaterlWater Vapour (H10)

- Air containsmoisture which is drawn into the compressorand enters the air stream as a vapour. Ascompressed air flows through the system, itcools, causing the vapour to condense in theface-piece or helmet . Moisture combines withoil and solid contaminants to form sludge,

IS 15879 : 1009

which can clog or damage system components .Water also causes rust in pipelines, and canfreeze in cold weather to block air flow.

c) Oil/Oil Mist - Oil is a major contaminant insystems using lubricated compressors. Inreciprocating compressors, lubricating oilappl ied to cylinders causes small droplets bythe shearing action of the piston to enter theair system as a mist. Oil mist can causebreathing discomfort, nausea and pneumonia,and create unpleasant taste and odours.

d) Solids - Solids generally enter the systemthrough the air intake. However, somematerials may be introduced by thecompressor itself. In non-lubricatedcompressors, teflon , carbon and othermaterials are used as lubricants. Frictionalwear can cause particles from these materialsto enter the air stream.

ANNEXB(Clause 6.5)

OPTIONAL ITEMS FOR BREATHING AIR PACKAGES

B-1 CONTAINMENT FILLSTATION FOR SELFCONTAINED BREATHING APPARATUS (SCBA)CYLINDERS

A front-loading, three position; containment fillstation can be included. The fill station shall totallyenclose the SCBA cylinders during the refillingprocess. The fill station shall contain the cylinderand any fragments of the cylinder and vent theexpanding air away from the operator in the unlikelyevent ofa cylinder rupturing while being filled.

The fill station's outer enclosure shall be constructedof6.25 mm thick steel. The fill station door shall beconstructed of 6.25 mm thick steel plate andreinforced by three 6.25 mm thick steel cylinderholders, providing a 12.5 mm thick steel protectivesafety barrier between the operator and the refillingprocess. The outer enclosure shall be welded intothe frame. The fill station shall be ergonomicallydesigned for maximum operator convenience andsafety for refilling cylinders. The fill station door andcylinder holder assembly shall tilt out towards theoperator, providing unobstructed access to thecylinder holder to load and unload the cylinders at

9

waist height. A slip resistant handle and heavy dutygas spring shall be incorporated into the design ofthe fill station to assist the operator in opening andclosing the fill station door.

Each cylinder holder shall be lined with ABS plasticstrips to prevent scuffing the outer surface of theSCBA cylinders. For complete operator protection,the fill station shall include a three-point pneumaticsafety interlock system that will prevent refillingSCBA cylinders unless the fill station door is closedand secured in the closed position. Three fill hosesshall be located within the fill station. Each fill hoseshall be equipped with a bleed valve and suitableSCBA fill adapters. Male adapters shall also beprovided to anchor the fill hoses when not in use.

B-1 CASCADE FILL CONTROL PANEL FORSCBA OR SELF CONTAINED UNDERWATERBREATHING APPARATUS(SCUBA) CYLINDERS

A stainless steel cascade fill control panel shall beinstalled on the front ofthe station. The control panelshall be factory piped for four storage banks anddesigned to fill three SCBA or SCUBA cylinders

IS 15879 : 2009

either independently or simultaneously. The controlpanel shall include, at a minimum, an automaticsto rage by-pass system , a manual control valve andpressure gauge for each storage bank, an adjustableregulator for SCBA cylinder fill pressure completewith a pressure gauge for inlet and regulated pressureand a reliefvalve to protect the SCBA cylinders fromoverfilling, a manual control valve and pressuregauge for each fill position, prov isions for factory orfield modification to allow a different fill pressure ateach fill position.

The automatic storage by-pass system shall controlthe dispensation of air from the compressor. Whenthe cascade fill operation is initiated by opening thedesired bank to fill from, the system will fill from thestorage bank selected. When the fill pressure andstorage bank pressure approach equalization theautomatic storage by-pass system will switch to directfill from the compressor. This will continue untilanother storage bank is opened or until filling iscomplete.

All control panel mounted pressure gauges shallhave a 100 mm diameter and be liquid 'fi lled. Afluorescent light shall be factory installed above thepanel to provide a glare-free illumination of thecontrol panel. A panel mounted on/otT switch shallbe supplied for the light. All panel-mounted

components shall be labelled with an engravednameplate.

B-3 HOSE REEL FOR MOBILE CASCADE FILL

Hose reel assembly shall be of sufficient size to hold16 m of 41.4 MPa (g) rated hose along with su itablehigh pressure coupler assembly. It shall be wall­mounted and contain a spring re-wind reel. The hosereel shall be controlled via a panel-mount valve andgauge located on the fill stat ion control panel. It shallinclude a hose mounted line valve, bleed valve, andhigh-pressure coupler assembly. The reel shall havea hose guide and hose stop.

8-4 AIR ANALYSIS KITS

The air analysis kit shall be capable of verifying thefollowing :

a) Oxygen content,

b) Carbon dioxide content,

c) Carbon mono xide content,

d) Methane content,

e) Water vapour content,

f) Dew point,

g) Oil/particles present, and

h) Odour.

ANNEXC(Foreword)

COMMllTEE COMPOSITION

Compressors, Blowers and Exhausters Sectional Committee, MED 22

Organization

Bharat Heavy Electricals Ltd, Hyderabad

ABB Ltd. Kolkata

ACC Machinery Company Ltd, Butibori

Atlas COpeD (India) Ltd. Pune

Bhant Pumps .t Compressors Ltd. Allahabad

Central Mine Planning .t Design Institute Ltd. Kolkata

Elgi Equipments Ltd. Coimbatorc

Engineers India Ltd. New Delhi

10

Representativets)

SHill AIlVINO G UPTA (Chairman)

SHill GAUTAM SEN

SHRI AIlUNABHA MUKHERJEE (Alternate)

SHill JAVANT KUMAR

SHill K . R. BALASUBIlAMANI (Alternate)

SHill J . M . KAUL

SHill K . N . SIDHWANI (Alternate )

S Hill V. K . SIlIVASTAVA

SHill SUIlAJ S,NGH (Alternate)

SHill R. DASG UPTA

SHIll D . S UNDEll RAtAN

SHill RAVINDIlA K UMAR

SHill A . K. NIJHAWAN (Alternate)

Organization

Fact Engineering & Design Organizat ion, Cochin

Gas Authority of India Ltd , New Delhi

Hindustan Petroleum Corporat ion Ltd , Mumbai

Indian Register of Shipping , Mumbai

Ingersoll-Rand (I) Pvt Ltd, Ahemdabad

Kirloskar Pneumatic Co Ltd , Pune

Ministry of Defence, Pune

National Fertilizers Ltd , Panipat

National Physical Laboratory, New Delhi

Newman & Essar Compressor Appl icat ion. Centre, Pune

Projects & Development (Ind ia) Ltd , Noida

Reliance Industries Ltd , Mumbai

Research, Design & Standards Organization , Lucknow

Revati Chicago Pneumatic India Ltd , Nasik

Steel Authority of India Ltd, New Delhi

Tata Chemicals Ltd , Badaun

BIS Directorate General

IS 15879 : 2009

Representativets )

SHRIV.G .SANKARANARAYANSHRI C. RADHAKRISHNA P. (Alternate)

SHRI R. S. JAwALE

SHRI B. K. NAMOEOSHRI M . RAMBABU (Alternate)

SHRI U. S. KALGHATGlSHRI R. K. KALRA (Alternate)

SHRI SURESH KAUL

SHRI SHRIDHAR V.NAIl(SHRI S. K . DESMUI(H (Alternate)

COL V. V. KADAMLT-CoLSANJAYA KUMAR (Alternate)

SHIU S. K. SHARMASHRI RAMAN GAMBHIR (Alternate)

SHIllJ. C. SHARMASHRI H. N. P. POODAR (Alternate)

SHRI SIIANXAIl CHA1TOI'ADYAYSHRI GOUTAM HALDER (Alternate)

SHRI ANIL KUMAR GUPTASHRI D. K. VOHRA (Alternate)

SHRI S. K. GARYALISHRI RANJIT S. MUNDRA (Alternate)

SHRIAruLYA SINHASHRI O. P. CHAUBEY (Alternate)

SHRI ANILK. LALSHRI V. S. MATHUR (Alternate)

SHRI B. P. SINGHSHRI S. K. JHA (Alternate)

SHRI C. P. CHHABRASHRI BHASKAR KUMAR (Alternate)

SHRI C. K. VEDA, Scientist 'F' and Head (MED)(Representing Director General (Ex-officio»)

Member Secretary

SHRI J.A. SIODIQUIScientist 'E' (MED), BIS

11

Bureau of Indian Standards

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connected matters in the country.

C opyright

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of necessary details, such as symbols and sizes , type or grade designations. Enquiries relating to copyright be

addressed to the Director (Publications), B1S.

Review of Indian Standa rds

Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed

periodically; a standard along with amendments is reaffirmed when such review indicates that no changes areneeded; if the review indicates that changes are needed, it is taken up for revision . Users of Indian Standardsshould ascertain that they are in possession of the latest amendments or editio n by referring to the latest issue of' BIS Catalogue' and 'Standards: Monthly Additions' .

This Indian Standard has been developed from Doc No.: MED 22 (1004).

Amendments Issu ed Since Pu blic a t ion

Amendment No. Date of Issue

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