Instrumentation Tools

Instrument Air System Design Excel Tool for Design Engineer

Instrument air systems serve a crucial purpose of supplying clean and dry compressed air for instrument and controls in industries. Built and named as the “Instrument Air System Design Excel Tool”, this is quite comprehensive that provides the approximate calculations engineers need to apply while designing the instrument air systems and evaluating their performances. This guide outlines what the tool does, how to use it, and why you should use the tool.

The “Instrument Air System Design Excel Tool” is one of the most valuable tools engineers working in the instrument air systems design and maintenance departments should possess. The benefits associated with the use of the tool include; user-friendly interface for the calculations and precision of the output, efficiency and flexibility in the design of air systems.

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This Instrument Air System Design Excel Tool is organized to help generate comprehensive and precise design information for instrument air systems. Key elements of the tool include:

  • Clearly marked fields for entering design parameters like stroke length, actuator diameter, and environmental conditions in Input section (Red colour).
  • Automatically computed values such as actuator volume, air demand, and required storage capacity in output section (Green colour)
  • The Excel file integrates formulas with Built-in Calculation Logic  to deliver accurate results based on user inputs.
  • The tool uses color-coded cells (e.g., Red for inputs and green for outputs) to guide users for user-friendly.
  • Actuator stroke length (meters)
  • Actuator stroke diameter (meters)
  • Environmental parameters
  • Number of instruments
  • Total air demand (calculated in cubic meters)
  • Actuator volume
  • Air receiver capacity
  • Power of the instrument air compressor
  • Modify input values to simulate different operational scenarios.
  • Evaluate how varying conditions affect air system requirements.

Uses standardized formulas to compute:

  • Actuator volume based on stroke length and diameter.
  • Shut-down valve air demand.
  • Storage requirements for continuous operation.
  • The tool generates a summary of inputs and outputs, which can be exported for documentation or review.
  • Download the Excel file and open it using Microsoft Excel or compatible software.
  • Locate the green highlighted cells in the “Instrument Air” sheet.
  • Input key parameters, such as: Actuator dimensions, Stroke length and diameter. Number of actuators
  • Adjust inputs to explore different system design options.
  • Use Excel’s export functionality to save results in PDF or printable formats.
  • Design Professionals responsible for designing instrument air systems in industrial projects.
  • Maintenance Personnel tasked with troubleshooting and optimizing existing air systems.
  • Project Managers  Individuals involved in planning and budgeting air system requirements for new installations.
  • Process Engineers working in sectors where pneumatic control systems are critical.
  • The Instrument Air System Design Excel Tool is applied in different industrial complexes like oil and some gas production units, refineries, and chemical companies. 
  • It has several application when it comes to automation systems since it helps in managing pneumatic instruments and the control systems appropriately. 
  • Design of air systems particularly in new projects would be most useful in the project initiation phase to determine air necessities and design them. 
  • As well as it is crucial for maintenance and upgrades: it helps to fine-tune existing system for better reliability and performance.

The pressure of an instrument air system in a chemical plant typically ranges from 7 to 12 bar (101 to 174 psi). The exact pressure depends on the type of instruments and equipment using the air. For instance, control valves often require higher pressure compared to safety systems.

Instrument air is compressed air used to operate instrumentation and control devices in process industries. It is essential in sectors like oil and gas, powering pneumatic devices such as control valves, actuators, and tools.

Instrument Air Requirement Formula:
Instrument air (peak demand, scfm) = 70% CV at steady state + 30% CV at transient + 20% SDV at transient.
Example: Instrument air (peak demand) = 70% x (5 x 1 scfm) + 30% x (5 x 6.25 scfm) + 20% x (5 x 4.8 scfm).

To size an air compressor, multiply the total CFM(cubic feet per minute) by 1.3 to account for a 30% buffer for future needs. Additionally, calculate the storage tank size by multiplying the CFM by 5 to ensure sufficient air storage.

To calculate air volume, use the formula for room volume:
Room volume = length (m) x width (m) x height (m).
The air change rate (ACH) for the room’s purpose is then used to determine the required air volume.

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Sundareswaran Iyalunaidu

With over 24 years of dedicated experience, I am a seasoned professional specializing in the commissioning, maintenance, and installation of Electrical, Instrumentation and Control systems. My expertise extends across a spectrum of industries, including Power stations, Oil and Gas, Aluminium, Utilities, Steel and Continuous process industries. Tweet me @sundareshinfohe

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