multiple air compressor control

The strategies we discuss below may not necessarily be applicable to centrifugal compressor systems. To make sure that all compressors are aligned, the pressure transducers would have to be calibrated perfectly with one another. This is the worst-case scenario when the system is fully loaded. A look at signals, differentials and set points is the first step to understanding the complexity of a system operated only by on-board controllers. If you can upgrade the filter styles, upsize the air dryers and increase the piping’s capacity, you can then decrease the pressure differential and be better able to deliver the required air pressure to the end-user. Consider the same situation as before, but with a mobile alert notification built into the control system that immediately notifies the service provider. This technology allows us to check your machinery’s condition so your production can continue without any interruptions. Perhaps a call to your vendor may be in order to improve your operating system to maximize reliability and efficiency. If an issue with your equipment arises, you can rest assured that we will contact you right away and discuss how we can resolve the problem before your business experiences any disruptions. All Rights Reserved. Many parts are chosen simply because they fit the standard available sizes used in the plant — not necessarily because they’re the best components for the application. Can the air pressure delivered to the end-user be stabilized with the help of the compressor control? How can you align the signals, differentials and set points to eliminate waste and elevated pressure? However, this also causes the compressor to draw a vacuum at the inl… Central Pneumatic Air Compressor Pressure Switch Control Valve With 1/4"PT Thread Safety Pressure Relief Valve,Replacement Parts 90-120 PSI 4 Port 240V Air Compressor Pressure. This causes the compressor to draw in less air, matching compressor capacity with air usage for relatively steady pressure control. The wrong combination of compressors is running. With this strategy, the machines will maintain the system’s pressure within the same acceptable band, allowing them to share the load. The sheets were collected daily and promptly stored in a place no one could ever find when needed. If the compressor is fixed-speed, it will be controlled by an inlet valve usually in a load/unload control mode, meaning the valve is 100 percent open or 100 percent closed. Without any help from us, the compressors could start, stop, load and unload to maintain the ideal pressure output and optimal energy consumption. Real-world conditions make it difficult to manage this pressure with precision, though. Effective system controls can be applied to any brand of compressor and linked for monitoring and control with many existing Distributed Control Systems (DCS). You value your time and money, and so do we. When AirLogix local control systems are not installed on all compressors, Case meets the challenge of managing multiple compressors of different compressor types and varying local control systems with … Elevated pressure wastes energy and creates artificial demand in the system. As the pressure decreases back at the signal location, the controller may load another compressor to meet the demand, however the pressure signal continues to decrease. If the world were perfect, controlling the pressure would be simple. To deal with this pressure inconsistency at the end-user, operators will often increase the compressor’s discharge pressure artificially to compensate for lower pressure. This feature avoids the potential for all compressors to inefficiently start and load in an attempt to quickly get the system pressure up to normal levels. This would change to about 115 psi when the loads are lightest. Start and Stop the compressor based on Dynamically matches the supply with demand using the most energy-efficient combination of compressors, Priority control for custom sequence selection and automation, Zone control and pressure balance function for compressors not co-located. And consider the reaction of the senior maintenance manager if he or she is contacted during his or her personal time. This issue applies to system elements such as: These components are not always installed properly, either. Proper control of a combined system of multiple reciprocating compressors requires parallel strategy, where all the compressors more or less start and stop together controlled by a … Now imagine how much energy this would expend if you did the same with 10 compressors! Imagine a system with three compressors, each of which has its own pre-filter, dryer and post-filter. This would generate about 15 percent more energy consumption at the compressor than is required for the demand. Trying to coordinate control of compressed air systems can be a frustrating experience at best, especially if there are multiple compressors located in different compressor rooms. Introduction: In my last article, we discussed the limitations of a single-stage air compressor and the problems associated with it. In the example above, the last compressor to start is set at the plant’s minimum allowable pressure, 90 psig. With ICONS, we can monitor your air compressor setup for you. If you have more than one compressor in local control, your setpoints spread over a broad range, which causes your first compressor to run at a higher pressure to maintain this control scheme. A Compressor Control Panel can control a single compressor or multiple compressors (Duty / Standby, Lead / Lag, etc.) FREE Shipping on orders over $25 shipped by Amazon. Perfect alignment is rarely the case due to various factors, including maintenance intervals and the air treatment equipment’s differing characteristics. Consider an air compressor with no remote connectivity generating an alert or tripping on alarm during a lower production shift where seasoned maintenance staff members are not available. An unmanaged control scheme for a bank of air compressors is a recipe for unnecessary consumption of power, as well as increased or unplanned maintenance. An example is anti-cycling control. The one that takes the partial load should also have the highest partial load efficiency. Even if you attempt to control the pressure farther down the line, such as between the dryer and the piping or between the piping and the FRL, you still won’t be able to eliminate the pressure differential issues that could arise at the critical end-user. These are located at the compressor’s discharge and before the treatment components, which are the filters and the dryer. We realize how important it is for you to keep your business up and running while simultaneously protecting your employees’ well-being and encouraging their productivity. However, if the loads vary widely, coordinating multiple compressors is virtually impossible. Compressors are operated efficiently when at full load. This is because fixed-speed rotary screw compressors tend to attain optimal efficiency when the load is full. In a normal cascaded pressure band arrangement, these machines would generally provide an air pressure of around 100 pounds per square inch (psi) when both compressors are fully loaded. While the sequencer had a common signal and pressure band, it did not have the intelligence to account for rate of change or size of compressor. Get it as soon as Thu, Feb 18. All three compressors also have their own pressure signals. If you’re using an unmanaged strategy for controlling multiple air compressors, you will experience unnecessary power consumption and more frequent or unexpected maintenance issues. For planned maintenance, a maintenance scheduler should also be specified. Storage … Without our central controllers, the load/unload pressure of each compressor can be set to react to changes in air demand. If the end-use applications of this air include pressure-sensitive tasks, this large pressure variation can cause a wide range of problems. When air is compressed, its temperature increases. Home » Blog » How To Manage Multiple Air Compressor Systems. With multiple compressors in local control, the set points are cascaded over a wide range, causing the first compressors to operate at elevated pressure to maintain the set point cascade control scheme. Pre-fill provides an energy-efficient method of increasing pressure to normal operating levels upon system start. When signals and differentials are mismatched, this will cause too many air compressors to run, which wastes energy and needlessly increases maintenance intervals. To deal with this pressure inconsistency at the end-user, operators will often increase the compressor’s discharge pressure artificially to compensate for lower pressure. as needed and generally operate as follows. In a fixed system, compressors may work in a pre-determined order to meet demand. With mismatched differentials and signals, too many compressors run, wasting energy and increasing maintenance intervals needlessly. Suppose the pressure signal is dropping at a certain rate based on a system demand event calling for more air. The compressor can only control the pressure of the air leaving the machine itself, but not once it has passed through other system components. The compressors control the pressure of the air leaving the system. If you’re controlling your system manually and following a procedure using local pressure settings, you’re likely wasting a lot of energy. Find out how Canfor Southern Pine as improved their operation by switching to Quincy Compressor. For more information, contact Chad Larrabee, Ingersoll Rand Company, tel: (704) 655-5370, email: Chad_Larrabee@irco.com, or visit www.irco.com. This issue applies to system elements such as: © 2021 Quincy Compressor. Unless the air treatment components and piping cause the exact same drop in pressure, your compressors won’t be aligned. Another factor that influences this control scheme is how much of a pressure drop there is from where the compressors discharge the air to the receiver tank, which is downstream from the air treatment components. The pressure here — where the critical end-user is — needs to be accurately controlled. Reminders and planners are possible so no maintenance is missed, creating confidence in uptime and reliability of the equipment. If the pressure is not kept above a certain minimum level, the machines powered by the compressed air will no longer function properly, which may disrupt production. Set up Compressors to Accept Remote Commands 4. In addition to dynamically matching supply with demand, increased functionality is built into some system controllers to ensure improved efficiency and fewer compressors running. The only exception would be if the compressors could somehow share loads with all units operating at partial loads. The plant production would be at risk as the plant personnel must now react to the interruption in compressed air supply. Central control in association with compressors usually signifies relatively intelligent control systems. There are several different methods to accomplish surge control: nually surge e compressor to set up the control system. We could easily set compressors to the minimum required air pressure. Ingersoll Rand Air Compressors and Services group offers a complete range of air compressor installation and integration services. Test, Tune and Measure You can achieve both of these things without having to raise the discharge pressure and waste energy. The type of individual compressor part load control is important to the efficiency of the system. Keep in mind that plants often have several hundred critical users, and controlling the air pressure for all of them is simply impossible. If the motor speed controls your compressor, “setpoints” become “target pressure.” If you have more than one compressor in local control, your setpoints spread over a broad range, which causes your first compressor to run at a higher pressure to maintain this control scheme. Cutting edge energy saving features and high reliability... We ensure your compressor is ready when needed. We could easily set compressors to the minimum required air pressure. This notification system can even let the provider restart the air compressor if they offer permission for this action. EnergAir worked closely with plant personnel to audit the Ottawa plant’s compressed air system in the Summer of 2012. If your compressed air system is controlled manually and you set up a control strategy using local compressor … Without any help from us, the compressors could start, stop, load and unload to maintain the ideal pressure output and optimal energy consumption. Controlling air compressors with only their on-board controllers can cause one or more of the following problems: How does this occur? What is possible, however, is designing high-quality, reliable components that feed the end-user.

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