Retrofitting 8 Varied Fired Units on the PF3100 Platform

The Profire Solution

Profire delivered a single-source modernization that brought all 8 fired units onto one consistent control platform. After an initial scope-out of the plant, our team handled the work end to end, from mechanical modifications through commissioning, startup, tuning, and emissions reporting. The only element outside Profire’s scope was the site’s electrical work.

At the core of the upgrade were 8 PF3100 BMS controllers, one per unit. Standardizing on a single controller platform meant every heater, from the cabin heaters to the cogeneration heater, thermal oxidizer, incinerator, and glycol dehydrators, shared the same operator interface and underlying architecture, even though each vessel type followed different operating principles. That consistency simplified operation and made spare parts interchangeable across the site.

Key elements included:

• Standardized PF3100 platform: 8 PF3100 BMS controllers, one per unit, giving operators a consistent interface across a varied set of vessels.
• Fuel train modernization: Profire rebuilt or upgraded every unit’s fuel train, from targeted component swaps to complete rebuilds, all brought up to current NFPA 87 code.
• Burner and pilot scope: New pilots for the two cabin heaters and the thermal oxidizer, and complete burner installs for the two glycol dehydrators.
• Self-checking flame supervision: Flame scanners with self-checking capability as part of a failsafe-by-design approach.
• Control room communication: Modbus to SCADA communication brought up to modern standards so Western can monitor and operate all units from the control room.
• Full-scope delivery: Scope-out, mechanical work, commissioning, startup, tuning, and emissions reporting delivered by Profire as a single source.

The Results:

With all 8 units modernized and running, Western reported positive early results, including no nuisance shutdowns and no outstanding complaints following startup.

The most immediate change was reliability. Replacing aging, inconsistent controls with a uniform PF3100 platform gave operators equipment that started and ran predictably, which reduced the manual intervention the old relight behavior had required. The fuel train upgrades and commissioning tuning also improved burner efficiency across the units.

Consistency proved to be one of the most practical benefits. Because every heater now runs the same panel, operators work from one familiar interface regardless of vessel type, which makes training and troubleshooting easier. It also lets Western stock a common set of spare parts that work across its installed base of heaters rather than managing unit-specific inventory.

Profire is proposing an annual preventive maintenance program to keep the units inspected and running well, giving Western a way to catch potential issues early rather than letting years pass between checks.