Compressor Controls

Compressor Control Systems

M-Tech Control can design and produce compressor control systems to meet your industrial needs. The global compressor market is growing due to: energy efficiency of compressors, increased automation in plants, variations in supply pressure, low maintenance requirements, and multiple fuel options. The emergence of next-generation compressed air systems and eco-friendly features of new technologies in compressors, are providing ample opportunities for growth in the global sector.

Compressors are used to compress gas and air from an initial low pressure to a higher final pressure. The compressor converts mechanical energy into pneumatic energy through compression; with the use of vanes, pistons, and other mechanisms. On the basis of inputs used, the global compressor market can be categorized as gas compressors or air compressors. The air compressor market can also be categorized on the basis of types, as centrifugal air compressors and positive displacement air compressors. On the basis of mobility, the compressor market can be categorized as stationary and portable. In construction and mining activities, portable products are generally used. Due to the convenience of transporting the equipment, portable compressors are a convenient power source for tools and machines in the construction industry. The convenience of handling portable compressors has also driven its implementation in low-duty applications.

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The global compressor market can also be categorized on the basis of technology used such as: screw, rotary, vane, and reciprocating. The market share of the screw technology category is expected to grow with a considerable rate in the coming years due to various features provided by technology such as; cast-iron cylinder, cooler running pump, oil lubricated pump, and additional motor protection. Reciprocating systems with oil-free scroll and dual cylinders offer enhanced performance and productivity, which is further supporting the growth of the global compressor market.

On the basis of end users, the global compressor market can be categorized as: chemical, pharmaceutical, cement, foundries and forge shops, glass, construction, plastic processing, automotive manufacture, and textiles. The global compressor market can also be categorized as per the requirement of the application into: horizontal or balanced opposed, single or multistage, lubricated or non-lubricated compressors, electric driven or diesel engine driven, and air-cooled or water-cooled.

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Types of Air Compressor Controls

Air Compressor controls are designed to match air compressor delivery with compressed air demand, by maintaining the compressor discharge pressure within a specified range. This discharge pressure should be set as low as possible to minimize energy use. Control strategies need to be developed using a systems approach, considering system dynamics and storage. There are six basic types of individual compressor controls:

Start/Stop: Turns the motor driving the air compressor on or off in response to a pressure signal (reciprocating and rotary screw compressors).

Load/Unload: Allows the motor to run continuously, but unloads the air compressor when a predetermined pressure is reached. The air compressor reloads at a predetermined lower discharge pressure. This type of air compressor control is also known as constant speed or constant run control (reciprocating, centrifugal, and rotary screw compressors).

Modulating: Restricts inlet air to the compressor to progressively reduce air compressor output to a specified minimum, at which point the compressor is unloaded. Also known as throttling or capacity control (centrifugal and rotary screw compressors).

Dual/Auto Dual: For small reciprocating compressors, allows the selection of either start/stop or load/unload. Dual/auto dual provides modulation for lubricant-injected rotary screw compressors to a pre-set reduced capacity, followed by unloading with the addition of an overrun timer to stop the air compressor after running unloaded for a pre-set time.

Variable Displacement: Allows progressive reduction of the air compressor displacement without reducing the inlet pressure (Reciprocating (multi-step) and rotary screw compressors (turn, spiral, or poppet valves)).

Variable Speed: Adjusts the air compressor capacity by varying the speed of the electric motor driving the compressor in response to system signals.

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M-Tech's Role

M-Tech Control can design a suitable compressor control system that fulfills your needs and application functionality. We can build a completely custom industrial control panel not offered online. Equipment manufacturers that need a standard product can count on M-Tech to deliver a consistent, clean, and worry-free product. OEM panels are a large part of our business. Contact us if you have a custom request.

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