Ref Document No.: AEC/22-23/2348/CP/00 Date: 11.06.2022 SoS AIRRO Ainpe ENGINEERING CO. Control Philosophy For HEATLESS AIR DRYER 1000 CFM @ (-) 40 °C Dew Point (ADP) CLIENT SHRIRAM ALKALI & CHEMICALS (DCM SHRIRAM LTD.) PONO, SAC/B02/4250009725 Dated: 20.05.2022 YEAR OF MFG. : 2022-23 OFFICE &. WORKS: 476, Manjusar_ GIDC, Manjusar, Savli Vadodara Phone:-91-2667-290376, +91 9099982714,+91 9099982715 Email: airroengineeringco@gmail.com wwwairroengg.comControl Philosophy Protocol Page 2 of 8 System: Desiceant Type Air dryer Cap: 1000 CFM. | Client: Shriram Alkali & Chemicals Document No.: AEC/22-23/2348/CP/00 [ Prepared by: Airro Engineering Co. 1.0 Objective 2.0 Scope 3.0 System description 4.0 Electrical Interlocking/ fault Alarm detail of Air Dryer 5.0 Check points were carried out for operation 6.0 Technical Specification 7.0 Working Phenomena of Air Dryer 8.0 Normal Start-up & Shut down 9.0 Approval SheetControl Philosophy Protocol ; Page 3 of 8 System: Desiecant Type Air dryer ‘Cap: 1000 CRM Client: Shriram Alkali & Chemicals Document No.: AEC/22-23/2348/CP/00 Prepared by: Airro Engineering Co. 1, OBJECTIVE To prepare detailed specifications for all the major components ofthe Desiccant Air Dryer so as to ensure thatthe user requirement specifications and functional specifications (ofthe data sheet) are achieved To design the Heatless Air Dryer in conjunction with the design data and to provide basis forthe vendo, ‘manufacturer, design enginer for designing the system when project bens. ‘The Purpose of this study to ensure the proper selection and installation ofthe Equipment Instrument at M/s Shriram Alkali & Chemicals (DCM Shriram Ltd) to comply withthe process, safety and regulatory requirements. This study verifies: * Qualification of the unit installation and examination of all background information is performed to assure conformance of project requirements of M/s Shriram Alkali & ‘Chemicals (DCM Shriram Ltd.) and manufacturer's specifications. * The equipment meets the current Good Manufacturing Practices (PMP) requirements and all other regulatory obligations. * No unauthorized or unrecorded modifications have taken place. * Operating Procedures/ Preventive Maintenance Procedures (PMP) have been identified and listed All critical instrumentation has been identified, All safety features are accounted for. All utilities are properly connected. 2. SCOPE ‘The scope of this design qualification is that Heatless Air Dryer is designed and manufactured according to appropriate standards and regulation, SYSTEM DESCRIPTION Equipment Name Heatless Air Dryer Manufacturer Airro Engineering Co. Customer ‘Mis Shriram Alkali & Chemicals (DCM Shriram Ltd.) ~Jhagadia Model Heatless Type Heatless Ai r drying unit is fully automatic and is used to remove moisture present in the compressed air coming out of Air Compressor at certain temperature and pressure. Air foam the Air Compressor is fully saturated with water vapors at ambient temperature. By using this Air Dryer, air gets dried up to (-) 40° C pressure dew point i.e. moisture content of the compressed ait cor down to less than 10-15 PPM Heatless Air Drying Unit has two towers filled with Acti AIRRO ENGINEERING ede t INE]Control Philosophy Protocol | Page 4 ors System: Desiccant Type Air dryer Cap: 1000 CFM : Client: Shriram Alkali & Chemicals Document No.: AEC/22-23/2348/CP/00 Prepared by: Airro Engineering Co, Alumina desiccant for continuous drying operation, At a time, one tower is used for drying of compressed air while the other tower is reactivated simultaneously. After a fixed time of interval, the drying towers get changeover automatically by operation of sequence timer and interconnected valves. In this design, reactivation of desiccant has been done by continuous purging a dry air through the bed in reverse direction. Reactivation is done at atmospheric pressure and temperature. Referring to the flow diagram, assume that the left tower is under DRYING and the tight tower is under REACTIVATION. Air enters the tower from bottom side, passes up through the desiccant and comes out from the top. A small bleed flow is split from the exit dry air and enters the right tower at atmospheric pressure. This bleed air picks up the moisture from the desiccant and vented ‘out to the atmosphere. After complete reactivation of desiccant, direction of control valves is reversed to place the left tower on reactivation and right tower on drying. Pre filter with automatic drain trap is provided to remove any physical moisture from compressed air before entering air to Drying Vessel. After filter is also provided in the dryer outlet line to arrest any desiccant dust particles up to 5 Micron size. Thus, absolutely "Clean and Dry" air is ready from the Dryer. 4. Air Dryer Desiccant Type working phenomena: ‘+ Dew Point Temp. Based Change Over: Set Dew Point Temp. As per Customer Required, Dew Point Temp Low As per set Temp. Sequence of Air Dryer run as per standard Cycle & Dew Temp. Ok Sequence Stop & Both Exhaust Valve will be Closed & Air Goes to Drying tower same as working conditions, 5. Check points were carried out for operation. Air Dryer Start, Sequence is On & As soon as pressure reaches 8.0 Kg/Cm2g, ‘The Air Dryer all changeovers working satisfactorily Dew Point Meter is working and showing the Dew Point Temp. Air Dryer Working parameters: > Air Dryer Tower Pressure ~ 7.5-8.0 kglem2g, > Dew Point Temp —(-) 40°C ADP AIRRO ENGINEERING GQ.Control Philosophy Protocol System: Desiccant Type Air dryer Page 5 of 8 Cap: 1000 CFM Client: Shriram Alkali & Chemicals Document No.: AEC/22-23/2348/CP/00 Prepared by: Airro Engineering Co. 6. TECHNICAL SPECIFICATIONS SR. DESCRIPTION PLANT DETAILS NO. 1 | FLOWRATE 1000 CFM | 2 | INLET AIR CONDITIONS: Relative Humidity 100% Gi) Inlet Working Pressure 8.0 Kgiem2G | GiiyTemperature 40°C- 45°C 3 | QUTLET AIR CONDITIONS: (@Dew Point (40°C PDP GipPressure 7.5 Kglem2G | (ii)Temperature Ambient 4_| TYPE OF DESICCANT USED ‘Activated Alumina 3 | PRESSURE DROP THROUGH 0.5 Kyfem?g (Max) UNIT 6 | Design Details: (@ Design Pressure 8.8 Kg/em2 g (i)Design Temperature 65°C 7 | Filter Used in the System: 1) Pre Filter (TW+1S) 2) After Filter Borosilicate Glass Fiber Type Filter (1 Micron) PP Candle Type Filter (5 Micron) 7. Working Phenomena of Air Dryer: ‘These are two towers filled with special grade of Activated Alumina desiccant to adsorb ‘moisture present in the incoming compressed air. At the bottom of each tower, M.S. performed plate with 10 mm diameter holes at 20 deg pitch and | mm thick S.S perforated sheet is welded to hold the Activated Alumina bed. Just above the sheet, the Ceramic balls are pulled to act as a holding bed for Activated Alumina, Alumina are filled up to the straight portion of towers and covered by a perforated plate which is welded with the top cover. A 50 mm thick coconut fiber met is putted on the top of Activated Alumina bed and squeezed together when the top cover is tightened. Wet air enters the tower from the bottom side nozzle through a 3-way control valve and dry air comes out from the top side nozzle, AIRRO ENGINEERING C.Control Philosophy Protocol Page 6 of 8 System: Desiccant Type Air dryer Cap: 1000 CFM. Client: Shriram Alkali & Chemicals Document No.: AEC/22-23/2348/CP/00 Prepared by: irro Engineering Co, © CYCLE OF OPERATION: ‘One tower remains in drying operation for 5 minutes and other tower under reactivation for 4 minutes. After complete reactivation or I-minute before of changeover, exhaust valve of the tower closes by getting signal from sequence programmer so that the pressure in both the towers equalizes. | REACTIVATI Reactivation of the desiccant is done by purging a small quantity of outgoing dry air. This purge air uniformly removes the moisture from desiccant. This purge flow of dry ar is taken from the outlet of dry air line. It is expanded from line pressure to near atmospheric pressure in the orifice plate before entering through the desiccant and gradually regenerates the desiccant at atmospheric temperature and pressure. This air dryer unit is being operated on 5 + 5 MIN cycle time, i.e. there are two dryings towers in the unit. Each tower remains in drying cycle for 5 Min Production & at the same time, other tower remains under regeneration and hence eycle goes on for infinite time. © Each Tower comprises of the following valves and instruments: © Air inlet valve (ADV-1) © Outlet valve as non-return valve © Exhaust valve (ADV-3 for Tower-1 & ADV-4 for Tower-2). © Besides, as in Dryer unit, there is a purge line at the top for the flow of purge Air at the time Reactivation, However, the purging is continuous, except for the equalization time. This ensures better dew points over long period of operation. Air Dryer pr. is 7.5-8.0 kg/em2 g. ‘To Sequence chart for Air Dryer Unit is explained as under: * Considering that Tower-I is under adsorption, ADV-I (Inlet valve Tower-1) and ADV-3 (Tower-II exhaust) are open and ADV-3 (Exhaust valve Tower 1) are closed. * Dry air passes out of the Tower-l through outlet non-return valve, A part of the dry air passes through the purge orifice and drags out the moisture of Tower-I * After 4 Min, ADV-3 (Exhaust valve Tower-II) closes. Since purge is continuous, the air fills up Tower-II equalizing the pressure of both the towers. This eliminates all sorts of pressure surges due to changeover. Finally, after § Min hours, ADV-1 (3 way Valves Change Our position) by changeover contacts. This ensures Air flow from Tower- Il. After 5 Sec, ADV-2 will open venting the air in Tower—I to atmosphere and starting its regeneration * The cycle of continuous for Tower—1 also and in this way, both the towers together continue. the drying process. INE RS AIRRO ENGINEERING(0¢, CNET S)Control Philosophy Protocol Syster Cap: 1000 CFM Document No.: AEC/22-23/2348/CP/00 Prepared by: Airro Engineering Co, 8. NORMAL START-UP AND SHUT-DOWN A) START-UP PROCEDURE: 1, The area near the unit should be kept clean. 2. Check that all electrical are O.K. Power and Control panel is getting power supply. 3. Check the Zeroing of all instruments, 4. Ensure that manual drain valves of all equipment are closed. 5. Switch ‘ON’ the main switch & control supply switch and accept ‘hooter. 1. Start Air Compressor. 2. Open the inlet ball valve up-siream from the air dryer to start the air flow through the unit. Close the valve if itis open, 3. Check the equal pressure in both the drying towers and ‘S\ the unit. +h ON” SW-1 the power supply to 4. Observe the operation of the Units for some time and see that the Dryer unit is working all right. ‘Check that the pressurization and depressurization of towers are O.K. 5. The dryer is now ready for operations. 6. Checked Function of Dew Point Meter, its working properly & Showing reading as per requirement. B) NORMAL SHUT DOWN; 1, Switch off the power supply given to the system. 2. Close the air inlet and outlet valves properly 3. Release the pressure of the system. ©) EMERGENCY SHUTDOWN. In case of any emergency: ‘Switch-off the main control Supply. AIRRO ENGINEERING CiControl Philosophy Protocol ‘System: Desiceant Type Air dryer Page 8 of 8 ‘Cap: 1000 CFM Client: Shriram Alkali & Chemicals Document No.: AEC/22-23/2348/CP/00 Prepared by: Airro Engineering Co, 9. APPROVAL, Prepared ‘Name Department Mr. Manav Mehta Airro Engineering Co. Project Executive Checked & Approved By: ‘Name Department Mr. Apurva Chaudhary Airro Engineering Co. Project Manager AIRRO ENGINEERING CO.