Adsorber Sequence Control
Adsorber Sequence Control
Adsorber Sequence Control
CONTROL PHILOSOPHY
A guide reference
Sequence Control
There are two types of Sequence:
Continuously Running Sequences
During the Adsorber sequence the adsorber phases and adsorber switching valves are controlled.
The sequence hold continuously monitors when the adsorber sequence should be put on hold. It
stops the regeneration timers so that the sequence cannot move to the next adsorber phase.
Event Initiated Sequences
In automatic mode of operation, the Adsorber sequence start is initiated by the operator by
pressing HS-2402-201. i.e. changes adsorber operating mode from ‘automatic-stopped’ to
‘automatic- Running’. The sequence releases an adsorber sequence override that effectively
bypasses regeneration gas around the regeneration adsorber.
Adsorber sequence stop that is initiated by the operator (HS-2402-203) or a unit ESD shutdown
when in ‘automatic’ mode i.e., changes adsorber operating mode from ‘automatic-running’ to
‘automatic-stopped’. The sequence imposes an adsorber sequence override that effectively
bypasses regeneration gas around the regeneration adsorber.
Hot oil sequences that isolate the hot oil supply and return in the event of a high hot oil pressure
being detected.
For each type of sequence there are:
Operator switches that govern the operating mode of sequence.
Operator parameters that can be changed within set ranges to allow process
Optimization.
Engineer parameters for engineer access only for fine tuning sequence operation.
Adsorber Sequence
The Molecular Sieve Dehydration process is a batch type process. The adsorber switching
sequence operates continuously and repeatedly cycles each of the adsorber vessels through a
number of adsorber phases. The Sequence Structure for One Adsorber is as shown in Fig. 1,
which is continuously repeated.
The Sequence consists of two parts:
1. Adsorber Phase
Adsorber Phase during which there are normally no switching valve movements.
Instead the sequence is given below:
Monitors the phase operating conditions and valve positions to check that they
remain within the set limits and if there is a deviation either:
Initiates an Alarm or
Initiates an Alarm and Holds the Sequence (i.e. Stops the Regeneration
Timer)
Monitors the end of phase condition for proceeding to the next Adsorber valve
switching step which is either:
normally a combination of time & process conditions (automatic operation) or
operator request (manual operation).
If this does not happen within a pre-set time then the sequence either:
Initiates an Alarm and Continue to the Next Step or
Initiates an Alarm and Wait for the end of phase condition to be met.
Sequence alarms are enabled/disabled and alarm values are modified.
2. Valve Switching Step
In this step:
Valves are operated in sequence and the action is confirmed by the valve limit switch Position
and/or process parameter prior to the next valve action:
Adsorber Phase Status is Changed
Controllers are Reconfigured
Timers are Reset
Sequence Alarms are Enabled/Disabled and Alarm values are modified.
All the phases have a fixed time (engineer or operator adjustable) except for the adsorber
'standby' phase times that float. The adsorber ‘standby’ phase time = Adsorption phase time –
(Pressure Equalisation 1 + Gradual Heating + Heating + Cooling + Pressure Equalisation 2)
phase time.
ADSORPTION PHASE
VALVE SWITCHING
PRESSURE
EQUALISATION 1
PHSE
VALVE SWITCHING
GRADUAL HEATING
PHASE
VALVE SWITCHING
HEATING PHASE
VALVE SWITCHING
COOLING PHASE
VALVE SWITCHING
PRESSURE
EQUALISATION 2
PHASE
VALVE SWITCHING
STANDBY PHASE
VALVE SWITCHING
The regeneration system operates at a slightly higher pressure than the adsorption phase. Two
pressure equalization phases are necessary to protect the bed from any sudden changes in
pressure. These phases are:
Pressure Equalisation 1 – Increases the pressure in the bed via a bypass valve prior to
regeneration (Gradual Heating) commences.
3. Pressure Equalisation 2 – Decreases the pressure in the regenerated bed via a bypass
valve prior to being brought back into the adsorption phase.
Note:
The adsorbers operate in one mode only, 3 bed operations, as online maintenance to the
Molecular Sieve Drier Vessels or adsorber switching valves is not possible.
The Individual Adsorber Sequences are linked to each other so that the Individual Adsorber
Sequences are correctly phased-see Fig. 2.
Note:
The order of bed regeneration is fixed: V-2402A, then V-2402B and then V-2402C. This means
that the links between the individual adsorber sequences are also fixed.
1st Adsorber 2nd Adsorber
heating phase
Cooling phase
Pressure equalisation 2
Adsorption phase commission next phase
adsorber on adsorption Standby phase
Parallel adsorption
phase
Pressure equalisation 1
phse Stop adsorption and
switch to pressure Adsorption phase
Gradual heating
phase equalisation 1
V-2402A R S R S
V-2402B R S R S R S
V-2402C R S R S
Fig. 3: Three beds operation
Adsorber sequence
Adsorber V-2402A Regeneration
Si.No Phase Duration YV-2402-06 YV-2402-04 YV-2402-07 YV-2402-03 YV-2402-01 YV-2402-02 YV-2402-05 YV-2402-18
1 Adsorption > 906 O O C C C C C O
2 PE 1 <2 C C C C O O C O
3 Gr. Heating 30 C C O O C C C C
4 Heating 255 C C O O C C C C
5 Cooling 105 C C O O C C C C
6 Standby N/A C C O O C C C O
7 PE 2 <2 C C C C O C O O
Adsorber sequence
Adsorber V-2402B Regeneration
Si.No Phase Duration YV-2402-11 YV-2402-10 YV-2402-12 YV-2402-09 YV-2402-08 YV-2402-02 YV-2402-05 YV-2402-18
1 Adsorption > 906 O O C C C C C O
2 PE 1 <2 C C C C O O C O
3 Gr. Heating 30 C C O O C C C C
4 Heating 255 C C O O C C C C
5 Cooling 105 C C O O C C C C
6 Standby N/A C C O O C C C O
7 PE 2 <2 C C C C O C O O
Adsorber sequence
Adsorber V-2402C Regeneration
Si.No Phase Duration YV-2402-16 YV-2402-15 YV-2402-17 YV-2402-14 YV-2402-13 YV-2402-02 YV-2402-05 YV-2402-18
1 Adsorption > 906 O O C C C C C O
2 PE 1 <2 C C C C O O C O
3 Gr. Heating 30 C C O O C C C C
4 Heating 255 C C O O C C C C
5 Cooling 105 C C O O C C C C
6 Standby N/A C C O O C C C O
7 PE 2 <2 C C C C O C O O
1. Manual Mode
Manual Mode is only used during:
Unit Commissioning;
Unit Shutdown for Maintenance and Valve/Sequence Testing and On-line Problem
Solving.
Manual mode can be selected only when the 'automatic' sequence is stopped. When 'manual'
mode is selected, extreme care must be taken if the unit is either:
Operating; or
At Elevated Pressure;
Otherwise there is a significant risk of fluidising and damaging the adsorbent and/or equipment.
When in 'manual' mode many of the normal process checks are bypassed.
The following operator actions are possible only when the 'manual' mode is selected but not if
the 'automatic' is selected:
1. On/off valves can be operated individually for valve testing or to put adsorber valves into
correct position for any adsorber phase.
2. HS-2402-101 "Set Adsorber Phase"
If no adsorber phases are set and the adsorber switching valve positions match a three
adsorber configuration, then this pushbutton can be used to set the adsorber phases. The
possible configurations are:
Where:
ADS = Adsorption; HTG = Heating; STDBY = Standby
When the adsorber phases are set the adsorber phase timers are automatically reset. Once the
adsorber phase has been set any valve movement inconsistent with the indicated phase valve
positions result in a 'valve failure' alarm.
3. HS-2402-102A “Set Adsorber Phase - ADS/ADS/HTG”
HS-2402-102B "Set Adsorber Phase - HTG/ADS/ADS”
HS-2402-102C "Set Adsorber Phase - ADS/HTG/ADS”
To save time & mistakes, the adsorber switching valves can be set to one of the three normal
bed operating configurations. These push buttons:
- Close all adsorber switching valves that need to be closed
- open all adsorber switching valves that used to be opened.
4. HS-2402-103 ‘Step-by-Step’
Once the adsorber phase is set, it is possible to use this pushbutton to move the valve positions
to the next phase, ignoring the regeneration phase timer or the end phase conditions. This is
primarily used for checking valve sequence operation when the unit is shutdown and
depressurised but can occasionally be used for online problem solving under special operating
procedures by an experienced operator.
2. Automatic Mode
“Automatic” mode is used during the normal operation of the unit. The unit can only be switched
to automatic mode if the adsorber phases are set.
1. HS-2402-201: ‘Regeneration Start’ Sequence
Can only be activated if:
‘automatic’ sequence mode is selected and
adsorber phase is set with no phase set alarm active.
This starts the adsorber sequencing program which continues from the same position that was
present when the sequence was put on hold (HS-2402-202) or stopped (HS-2402-203). The
‘Regeneration Start’ sequence resets the adsorber switching valves YV-2402-03/09/14 and YV-
2402-18 that were set by the ‘Regeneration Stop’ sequence to bypass the adsorber on
regeneration.
Note:
The ‘Regeneration Start’ sequence does not open the regeneration gas flow valve FV-2403-01
which must be operated manually by the operator by taking FIC-2401-01A in manual mode and
increasing the output until the required flow is met then the controller can be taken in auto mode
with the desired setpoint.
Normal Operation
When the adsorber sequence is on ‘Automatic-Running’, the adsorber sequence cycles the
adsorbers through the required adsorber phases until either:
the operator 'Stops' or 'Holds' the sequence or
a sequence alarm 'Stops' or 'Hold's the sequence or
a unit ESD trip 'stops' the sequence.
If the operator 'Stops' or 'Holds' the sequence and then re-starts the sequence or releases the
'hold', the sequence continues. The sequence resumes in exactly the same position to that
before the 'Stop' or 'Hold'. If the operator wishes to restart the present phase again then this can
be done using HS-2402-204 'Reset Regeneration Phase Timer'.
If a sequence alarm 'holds' the sequence and the 'hold' condition is cleared then the 'hold'
condition is cancelled and the sequence continues from exactly the same position i.e. the
sequence continues even if the operator has not acknowledged the sequence ‘hold’ alarm.
If a unit ESD trip 'stops' the adsorber sequence, it is necessary to:
Reset the ESD Trip
Restart the 'adsorber' Sequence.
If a high water concentration is observed from the next adsorber vessel to be regenerated then
the operator can initiate early regeneration of this adsorber if there is a regenerated adsorber on
‘standby’ using the HS-2402-205 Adsorber adsorption switch.