ADSORBER SEQUENCE

CONTROL PHILOSOPHY
A guide reference

NOVEMBER 19, 2017

Asas contracting LTD

Molecular Sieve Dehydration
A PLC Control & Safeguarding System is used for controling & monitoring the following:
 Adsorber System Sequence Control
 Unit Start-up and Shutdown Sequence Controls
 Operator Controls for Unit Manual Operation
 Standard Continuous Control Loops
 Sequence and Standard Alarms
 Unit Monitoring and Operation Status Information
 Trending and Historical Records
 Unit Safety and Equipment Protection through ESD/PSD System.
The following information for the Molecular Sieve Dehydration Unit can be monitored:
 Displays with all process parameters and status information indicated on unit P&ID's.
 Sequence status information including adsorber phase information
 Sequence Operator Controls
 Sequence Operator Parameters
 Sequence Engineer Parameters (Password Protected)
 Adsorber Switching Valves Manual Operation
 Controller Measured Values, Set Point (Actual and Target), Output, Control mode
(Auto/Manual/Remote) and Status (Operator or Sequence control)
 Alarm Status Page – Common with Rest of Plant
 ESD Status Page – Common with Rest of Plant
 Parameter Trending.
Alarms: The unit alarms are annunciated by the PLC system and acknowledged/reset.
ESD Alarms: An ESD alarm triggers the ‘regeneration stop sequence’ and stops the adsorber
sequence.
Sequence Alarms: There are several types of Sequence Alarm as follows:
1. Phase Monitoring Alarms
When the adsorber switching valve positions are incompatible with the indicated phase &
when the process parameter exceeds the limits set by a sequence during an adsorber
phase, this type of alarm is generated.
2. End of Phase Failure Alarm
When a process parameter exceeds the limits & when the regeneration phase timer has
timed out, this type of alarm is generated. Such alarms are specified in the sequence logic.
3. Valve Failure Alarm (XSVALVEALARM)
The valve failure alarm is initiated if a valve position is not consistent with the output to
valve after delay for valve movement.
4. Valve Phase Failure Alarm (XSVALVEPHASEALARM)
A valve phase alarm is initiated when the indicated valve positions are not matching with
that expected during an adsorber phase.
5. Sequence 'Hold' Alarm
When the sequence has been put on 'hold' either by an alarm condition or by the operator
this alarm is generated.
Control
The molecular sieve dehydration unit control is a combination of :
1. Standard Plant Controller using either:
o Continuous PID Control or
o On/Off ‘Gap’ Control
2. Sequence Control for:
o Adsorber Phase Switching
 o Regeneration Sequence Start/Stop.
1. Standard PID Controllers
The following controllers are standard PID controllers with no sequence actions:
o TIC-2401-08 - Regeneration Gas Cooler Outlet Temperature
There are two air cooler fans:
 The variable pitch air fan is controlled by a direct acting Temperature Controller. The Low
measured temperature requires a reduction in the controller output to increase the
Temperature.
 The fixed pitch air fan (manually adjustable) is controlled by the sequence logic in on/off
mode
Recommended Set Point Value: 40°C
Recommended Alarm Value: High 60°C, Low 30°C
2. Standard On/Off Gap Controllers
The standard on/off [GAP Control] controllers with no sequence actions are as listed below:
 LIC-2401-02 – Molecular Sieve Inlet Separator Level
Recommended Set Point Value: 30% (500 mm) to 55% (750 mm)
Recommended Alarm Value: High 60 % (800 mm), Low 25 % (450 mm)
 LIC-2401-08 – Molecular Sieve Inlet Filter Coalescer Bridle Level
Recommended Set Point Value: 30% (500 mm) to 70% (900 mm)
Recommended Alarm Value: High – 75% (950 mm), Low 25% (450 mm)
 LIC-2401-12 - Molecular Sieve Inlet Filter Coalescer
Recommended Set Point Value: 30% (350 mm) to 60% (500 mm)
Recommended alarm value: High 68% (540 mm), Low 20% (300 mm)
 LIC-2403-01 – Regeneration Gas KO Drum Level
Recommended Set Point Value: 44% (700 mm) to 61% (850 mm)
Recommended Alarm Value: High 72% (950 mm), Low 33% (600 mm)

Sequence Controlled Controllers

Ability to ramp a controller Set Point is incorporated within the sequence logic for the following
controllers. The following are indicated on PLC display:
 Target Set Point
 Set Point
 Measured Variable
 Output

1. TIC-2402-04 – Dehydration Inlet Heater Hot Oil Return Temperature

This is a reverse acting Temperature Controller. The low measured temperature requires an
increase in the controller output to increase the temperature. It controls the hot oil return
temperature by acting on TV-2402-04. The controller output is maintained typically at a value of
10 to 15%. This is required to maintain a minimum hot oil flow through the heater & hence avoid
the temperature cycling.
In the event of a high hot oil pressure (PI-2402-20) – possibly due to an exchanger tube rupture -
the control system overrides the controller output and closes TV-2402-04.
Recommended Set Point Value: 191°C
Recommended Alarm Value: High 210°C, Low 170°C.

2. TIC-2403-04 - Regeneration Gas Heater Outlet Temperature

This Controller is a split range reverse acting Flow Controller. The low measured temperature
increases the controller output to increase the temperature. It controls the Regeneration Gas
Heater outlet temperature by acting on control valves TV-2403-04A and TV-2403-04B.
The Set Point for the controller is controlled by the regeneration sequence according to the active
regeneration phase. During the heating and cooling phases a Set Point ramp is required.
 TV-2403-04A and TV-2403-04B operate simultaneously and are complementary to each
other with opposite gains.
 When the Process Variable (PV) of controllers TIC-2403-04 is less than the Set Point, the
MV increases.
 On increasing MV, the valve B opens from 0 to 100% where as valve A closes from 100
to 0%, thus allowing more flow through the Regeneration Gas Heater (E-2403A/B).
 On decreasing MV, the valve B closes from 100% to 0% where as valve A opens from 0%
to 100%, thus bypassing the Regeneration Gas Heater (E-2403A/B).
 The valve B shall Fail Lock to Drift Open and valve A shall Fail Lock to Drift Close on
failure of the Instrument Air Pressure.
Recommended Set Point Value: Gradual Heating : 120-235°C
Heating – 235°C
Cooling (to be decided during commissioning phase)
Recommended Alarm Value: Gradual Heating: 150°C (H); 90°C (L)
Heating: 245°C (H); 220°C (L)
Cooling: 40°C (H); 30°C (L)
3. TIC-2403-03 – Regeneration Gas Heater Hot Oil Return Temperature
This controller is a reverse acting Temperature Controller. The low measured temperature
requires an increase in the controller output to increase the temperature. It controls the hot oil
return temperature by acting on TV-2403-03.
The controller output is maintained typically at a value of 10 to 15%. This is required to maintain
a minimum hot oil flow through the heater & hence avoid the temperature cycling.
Recommended Set Point Value: 182°C
Recommended Alarm Value: Low 175°C
4. FIC-2401-01A – Regeneration Gas Flow Rate
This is a direct acting Flow Controller. The low measured flow requires an increase in the
controller output to increase the flow. It controls the regeneration gas flow rate by acting on the
flow control valve FV-2403-01.
Recommended Set Point Value: FIC-2401-01A – 12660 Sm3/h
Recommended Alarm Value: FIC-2401-01A – (H) 14560 Sm3/h (L) 11500 Sm3/h

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

Figure.1: Sequence Structure for One Adsorber

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

Fig. 2: Typical Adsorber Sequence Links

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 phase Time

Adsorption 16+ hours
Pressure equalization-1 0.03 hours
Gradual heating 0.5 hours
Heating 4.25 hours
Cooling 1.75 hours
Pressure equalization-2 0.03 hours
Standby 1.44 hours
 V-2402A V-2402B V-2402C
HEATING PHASE
COOLING PHASE
PE 2 PHASE Adsorption
STANDBY PHASE
Adsorption
PE 1 PHASE
GRADUAL
S3 HEATING PHASE
S2 HEATING PHASE
PE 1 PHASE COOLING PHASE
Adsorption
GRADUAL
PE 2 PHASE
HEATING
HEATING PHASE STANDBY PHASE S2
COOLING PHASE
S3
PE 2 PHASE
STANDBY PHASE
S1
PE 1 PHASE
GRADUAL
Adsorption S1
HEATING
HEATING PHASE
COOLING PHASE
Adsorption
PE 2 PHASE
STANDBY PHASE
PE 1 PHASE
Adsorption GRADUAL
HEATING PHASE
Fig. 4: Three Bed Adsorber Sequence Links

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

Sequence Operation Modes

HS-2402-100: ‘Automatic/Manual’ Sequence Switch:
There are Two Sequence Operating Modes [Refer Fig. 6]:
 Automatic
 Manual

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:

ADS/ADS/HTG ADS/HTG/ADS HTG/ADS/ADS

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.

2. HS-2402-202: ‘Regeneration Hold’ Sequence

Regeneration Hold sequence stops the adsorber sequence program. It stops the sequence from
proceeding to the next step and halts the regeneration timer. It can be utilised by the operator to
extend the duration of a particular regeneration phase.
It does not:
 stop the inlet gas flow through the unit;
 stop the regeneration gas flow;
 stop the regeneration gas heating and cooling;
 stop the valve sequencing to next adsorber phase if already in progress.
3. HS-2402-203: ‘Regeneration Stop’ Sequence
Regeneration Stop sequence holds the adsorber sequence program (See HS-2402-202) and
arranges for the regeneration gas to bypass the adsorber being regenerated by opening YV-
2402-18 and closing the adsorber regeneration inlet adsorber switching valves YV-2402-
03/09/14. The regeneration gas flow is not stopped. Operator has to stop it by closing FV-2403-
01 manually.
4. HS-2402-204: Regeneration Phase Timer Reset
This resets the current regeneration phase timer so that the current regeneration phase is
restarted.
5. HS-2402-205: Adsorber Adsorption Switch
The operator can initiate early regeneration of the next adsorber to be regenerated in the event
that early breakthrough of water is observed during the ‘adsorption’ phase. However, this is only
possible if there is a regenerated adsorber on 'standby’ phase which must first be switched to
the adsorption phase.
Manual/Automatic 'adsorber' Sequence Switching
When the 'adsorber' sequence is switched from 'manual' to 'automatic', all the selected manual
valve positions are lost i.e. there are no manual outputs to the valves. If the adsorber switching
valve positions do not match the indicated adsorber sequence then a valve phase failure alarm
is initiated and the sequence does not run. This then requires the operator to either:
 Switch adsorber sequence to 'manual' and manually put valves in position consistent
with the indicated adsorber phases or
 Switch adsorber sequence to 'manual', put valves in position consistent with another
adsorber phase and 'Set adsorber phases'.
When the 'adsorber' sequence is switched from 'automatic' to 'manual' the outputs from the
'adsorber' sequence are cut but not lost. However there are no adsorber switching valve
movements as all valves are double acting.

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.