Instrument Air Dryer Automation

INDUSTRIES
  • Refining & Petrochemical
SERVICES
  • Training
  • Project Management
  • Program Management
  • Process Optimization
  • PLC
  • Operations & Maintenance Technical Support
  • Medium / High Voltage Design
  • HMI
  • Electrical Design
  • Drafting
  • Document Management
  • Detailed Engineering
  • Controls Commissioning Services
  • Construction Package Development
TECHNOLOGIES
  • Training
  • Project Management
  • Program Management
  • Process Optimization
  • PLC
  • Operations & Maintenance Technical Support
  • Medium / High Voltage Design
  • HMI
  • Electrical Design
  • Drafting
  • Document Management
  • Detailed Engineering
  • Controls Commissioning Services
  • Construction Package Development

The Challenge

The client, a petrochemical producer, required a modernization of instrument air dryer controls as well as a system that would eliminate the need to manually regenerate the dryer beds. Instrument air is a critical component of the client's process, and the procedure to dry compressed air in the existing apparatus was cumbersome and prone to incorrect level of dryness. Automating the process would provide for regular, time based drying of instrument air as well as the ability to initiate a dry sequence automatically by sampling the instrument air at the output.

Autopro's Role

The solution involved designing a control system that replaced/upgraded many of the valves on the air dryer. Autopro designed a control panel containing a PLC, instruments and timers, all of which were housed in a custom cabinet. The control panel was pre-tested at the vendor facility prior to shipment and installation. Autopro's scope of work included:

  • Conducting a complete analysis of the current system
  • Evaluating equipment and identifying alternatives that would meet client requirements
  • Designing the solution
  • Designing the PLC and HMI programming
  • Ordering equipment
  • Factory acceptance testing of the control system
  • Assisting with installing and testing the new system
  • Post-installation support, reprogramming and optimization

The new system automatically regenerates on either timed or load based parameters, and is also capable of performing manual regenerations. The project also included the implementation of communications capabilities to provide the Control Room operators with remote access to the air dryer, something that had not been possible with the previous design.

Project Success Criteria

The project was completed on budget and is performing well. The client also requested post-installation, on-site service to reprogram for optimization, something that was not  available to them with the old system. They continue to optimize the process on their own.

Project Metrics

Project Completion Date