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It actually takes a while for the entire air system to attain the desired Pressure. To overcome the lag in response time between Demand & Supply, Compressed air system is maintained at higher level of Pressure to meet the sudden demand, leading to wastage of compressed air and an inefficient energy system causing inflated energy bills.
ControlAiR Intelligent Flow Control System (IFC) reduces artificial demand by controlling the air flow and pressure being delivered to the plant. It is designed to operate at an intermediate point i.e. on the downstream side of the air treatment equipment and upstream side of the main piping distribution system.
ControlAir IFC provides air at a controlled differential and optimum pressure, which reduces the mass of air consumed by pneumatic equipment, tools & amount of leakages, ultimately resulting in the reduction in energy consumed by Air Compressors.
Why There Is An Opportunity For Energy Saving?Every industry has problem of fluctuating air pressure. This is caused by intermittent use of several pneumatic equipments. It begins with sudden air demand pulling down pressure at the point of use. The only way for the Air Compressors to know about it, is when it travels to upstream through distribution network. The capacity control mechanism of the Air Compressor in the form of Load/Unload or VSD then starts delivering compressed air in the system. Practically it takes a while for the entire air system to fill up to the required pressure.
Benefits:- Saves Compressed Air Energy by 4-25% thought reduction in Artificial Demand
- Improves pneumatic equipment performance with constant air pressure within the range of +/-1 psig (0.07barg)
- Improves the response time of system to meet instantaneous demand
- Reduction in compressor’s operation and maintenance
- Reduction in compressed air leakages
- Works with all brands and types of compressors
- Payback period between 1-2 years
- Improves VSD Performance
ControlAir IFC is user friendly with HMI Touchscreen Colour Graphics Display showing multiple screens to exhibit following information.
- Dashboard screen display the Inlet pressure, Set Pressure, Actual Discharge Pressure, percentage opening of flow control modules, current status & error logs.
- Online Pressure Trend of Inlet and Outlet pressure.
- Run hours, Service due hours.
- Historical data of pressure values, errors w.r.t. date & time which can also be retrieved via the USB port.
Operational Features :-
- Remote Operation (Start/ Stop , Target Pressure setting)
- Preset Target Pressures can be remotely selected
- Weekly Programmable 28 Pressure settings scheduler
- Special program to work with Centrifugal compressors to avoid surge
- Optional PC conectivity
Click on the buttons inside the tabbed menu: :-
Key Specifications/ features
- Works with All Brands & Types of Air Compressors
- Saves Compressed Air Energy through reduction in Artificial Demand by 4-25 %.
- Fail safe operation through ‘Fail to Open’ modules and an additional Auto-Bypass Valve.
- Pressure set point resolution: 1 psi (0.07 bar)
- Pressure control in the range of: ±1 psi (±0.07 bar)
- Multi-Parallel Fast Response System gives better air pressure / flow control in the plant.
- Reduces leakages losses in the plant.
- Enhances useful storage capability.
- Isolates compressors from demand side peaks & troughs.
- Ease of setting the Optimum Plant Pressure.
- ControlAiR IFC is user friendly with the use of HMI Touchscreen Colour Graphics Display with multiple screens (Please refer the attachments for graphical screens and more details)
Applications
- Automobile Industry: Powering Pneumatic tools; atomize and propel paint through paint-spraying systems for even surface distribution; Powder coating; Tire inflation.
- Robotic machinery: Control of robotic machines on assembly lines.
- Cement plants: For blending, aeration, fluidization and conveying of cement.
- Pharmaceutical Industry: Tablet coating and production; Pneumatic conveyor of tablets for filling, packaging and bottling.
- Chemical Manufacturing & Process: Production and Pneumatic conveyor of PET resin beads; Operation of control valves and actuators; Fermentation & Aeration processes.
- Textile: Precision control of pneumatic valves and cylinders in spinning machines; loom jet weaing for insertion of weft; winding machine with the purpose of splicing of yarn; various processes such as bleaching, dying, sewing and printing on fabric; blow-off of residual/dust material.
- Paper & Pulp: Variety of press application; Precision control of rollers to control paper thickness.
- Food Industry: Blow-off applications; Cleaning containers before filling containers with food; other applications include sorting, air knives for cutting and peeling of fruits and vegetables, shaping of food products & packaging.
- General Manufacturing: Powering rotary equipment and tools; Sand blasting and cleaning; Pneumatic lifting equipment; Plasma cutting & welding.
Type
- IFC – Downstream Controller:
- IFC is designed specifically to operate at intermediate point of the compressed air system i.e. on the downstream side of the filter/ dryer/ receiver and upstream side of the main piping distribution system.
- UPC maintains reduced constant upstream pressure in compressed air system.
UPC – Upstream Controller:
