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Automatic Sequencer
An automatic sequencer is a control system that manages the operation of one or multiple air compressors in a system. It activates and deactivates compressors in a programmed sequence to efficiently meet fluctuating air demand, reduce energy consumption and minimize wear and tear. These benefits could translate into lower operating costs.
This air compressor control system can range from a simple on/off switch to a complex, computerized network that controls multiple compressors.
FAQs
A sequencer is most beneficial for facilities that operate multiple air compressors and have a significant and fluctuating demand for compressed air. Also, consider this air compressor control system if you notice high energy costs associated with compressing air.
An automatic sequencer saves energy by preventing multiple compressors from running at inefficient partial loads. Rather, it selects the most efficient combination of compressors to meet the current demand.
Smart sequencers are programmed with the specific performance data, such as flow rate and power consumption of each compressor in the system. Using this data, its algorithm calculates the most energy-efficient combination of machines to meet the real-time air demand, rather than just following a simple pressure-based order.
The main types include the cascade method, which uses sequential pressure setpoints and more advanced target algorithms that use different pressure bands for trim and base-load compressors. Modern automatic sequencers often use sophisticated algorithms to optimize compressor selection based on efficiency.
An automatic sequencer manages various compressors, such as fixed-speed rotary screw, centrifugal and variable speed drive (VSD) units, often integrating them to work together.
Without a sequencer, compressors often run in a cascade mode, resulting in wide pressure gaps between them. This setup leads to multiple compressors fighting for control, running inefficiently at partial load and causing rapid cycling. This system results in wasted energy and premature wear and tear.
A programmable logic controller (PLC) is often the core of an industrial compressor control system. It’s a rugged computer that executes control strategies, monitors sensors and automates compressor operations to improve efficiency and reduce the need for manual intervention.
Yes, by evenly distributing the operating hours among all compressors, it prevents any one unit from accumulating excessive wear, which helps standardize maintenance schedules. Many automatic sequencers provide maintenance reminders and alerts.
A compressor control panel is the central interface for operating, monitoring and managing an air compressor. It allows operators to start and stop the unit, set operating parameters like pressure and temperature and view real-time data.
Many modern control panels offer remote control and monitoring capabilities. These allow operators to remotely start, stop and adjust the compressor’s settings from a computer or mobile phone.
A smart compressor control incorporates artificial intelligence (AI) and machine learning to optimize performance. These systems can learn a facility’s air usage patterns and predict future demand, enabling more intelligent decisions about which compressors to run and when.
Yes, in most cases, it is possible to retrofit existing compressors with smart control systems. These controls provide modern features like remote monitoring and intelligent sequencing without replacing the entire compressor.