COMPRESSOR

© 2007 Compressor Controls Corporation. All rights reserved.

CONTROLS
CORPORATION
Compressed Air
Controls Solutions

Air Miser®

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 Air Miser® History
• 1985: Series II Air Miser was born
• Turbocompressor skid mounted control
panel
• Application functions included compressor
© 2007 Compressor Controls Corporation. All rights reserved.

surge control,performance control and master

load-sharing control
• Panel-mount transmitters and I/P
• Engineered to integrate with the existing
motor logic and auxiliary equipment controls
• Increased energy savings from reduced blow-
off, precise pressure control and minimization
of pressure set point
• Over 100 compressors retrofitted
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 2005 Air Miser® Control Panels
© 2007 Compressor Controls Corporation. All rights reserved.

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 New Air Miser® In a Nutshell
• Standardized and complete controls solutions
for packaged air compressors
• Pre-engineered control panels with standard
set of documentation (manuals, drawings, etc.):
– Air Miser TL for a single turbocompressor
© 2007 Compressor Controls Corporation. All rights reserved.

– Air Miser ML for master coordinated controls

• Optional panel mount components

• Optional Value and Instrumentation packages
• Powered by CCC advanced controls technology
– Powerful surge protection techniques
– Maximum turndown through patented load sharing
– Compressor network capacity management

• Field-serviced by CCC or an authorized rep

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 Control System Architecture
COMPRESSOR 1 COMPRESSOR 2

Deterministic
inter-controller
networking
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Machine Area
Air Miser Link (Up to 16 Nodes)

MASTER
MASTER Operator Area

RS485

Air Miser View

Remote OIT
HMI

RS485 MODBUS RTU/TCP

SCADA
or DCS GATEWAY-
Ethernet
SERVER
LAN/ WAN/Internet

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 Simplified Compressor P&ID

AM

1
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Inlet Valve To
Inlet Air Filter Atmosphere
M

Blow-Off
C-1
Valve

P-4

Check Valve
After Cooler Dryer
Receiver

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 Plant Air Compressor P&ID
um P&ID of a Typical 3-stage Packaged Air Compressor
(Shown Instrumentation Set is Supported by Standard Air Miser ® TL Control System)

TE JT TE TE VT PT PT VT VT PT TE
907 901 901 908 101 102 202 201 301 302 600

Silencer

Stage 2
FIC
FCV600
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Stage 1
TE TE
101 201
M001
PIC Stage 3 CV600
1
TE DPT TE PT*
301 600 601 601

E101 LS
PCV101
TE LS 702
Inlet Filter 701 701

Cooling E201 E301

SV702
Water Inlet To distribution
header

DPT
001 SV701

TS Optional Value Packages:

800
DPT TE PT
801 801 801 Flow and Efficiency
Oil drain
LS
800
Oil Tank Motor Monitoring

Heater
T800 Filter Monitoring
Lube oil inlet
CV800
E801 Oil Filter

P800

* System pessure is measured downstream of air dryers

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 Air Miser® TL unit control panel

Purpose-built for complete controls and

automation of a single 2 or 3-stage
packaged air compressor with either
electric motor or steam turbine drive
© 2007 Compressor Controls Corporation. All rights reserved.

Designed to completely replace an OEM

control panel or any inadequately
functioning control panel

Pre-programmed for major compressor

makes

Complies with API 672 specification

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 Air Miser®TL Compressor Control
Panel Hardware
NEMA 4 enclosure
System health indicators

8” VGA Touch Screen

© 2007 Compressor Controls Corporation. All rights reserved.

Operator Interface
Terminal with Pointing
Device

Control switches
and indicators

48” x 24 “ x 12”
1200 mm x 600 mm x 300 mm

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 TL Panel Inside View
I/O
Field Modules
Terminals
Health
Indicators
Controller
HMI
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Panel

24 VDC
Com
Power
Supply
Port
FTAs

Operator
AC Line Controls
Filter
Optional
Vibration
Transmitters
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 State-of-the-art Controller
• 22 Analog (4-20 mA or
RTD) Inputs
• 2 Analog Outputs
• 16 Discrete Inputs
• 14 Discrete Outputs
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• 1 Frequency Input
• All field I/O channels
feature galvanic isolation
from the field devices
• Two internal 24 VDC power
supplies
• 32-bit microprocessor
• Fast 5 ms I/O sampling
cycle
Analog Digital Digital • Non-volatile memory for
I/O Outputs Inputs
configuration storage
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 Analog Input Channels
Basic Set Options
1. Motor power (motor-driven 14. Motor winding temperature
machines) 15. Motor bearing temperature
2. Lube oil pressure inboard
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3. Lube oil temperature 16. Motor bearing temperature

4. Stage 2 inlet temperature outboard
5. Stage 3 inlet temperature 17. Inlet air filter differential
6. Aftercooler temperature pressure
7. Stage 1 discharge pressure 18. Oil filter differential pressure
8. Stage 2 discharge pressure 19. Compressor flow
9. Stage 3 discharge pressure 20. Stage 1 inlet air temperature
10. System (header) pressure 21. Cooling water temperature
11. Stage 1 vibration 22. Compressor discharge
temperature
12. Stage 2 vibration
13. Stage 3 vibration

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 Discrete Field I/O Channels
Inputs Outputs
1. Motor run contact 1. Motor start or start/stop
2. Auxiliary oil pump run 2. Motor stop only
contact 3. Aux. oil pump start or
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3. Oil reservoir temperature start/stop

switch 4. Aux.oil pump stop only
4. Oil reservoir level switch 5. Oil heater On/Off control
5. Seal air pressure switch 6. Cooling water solenoid
6. Cooling water flow switch On/Off control
7. Condensate level switch 7. Condensate drain solenoid
8. Danger from vibration On/Off control
monitor 8. Trip to DCS (annunicator)
9. Alert from vibration 9. Alarm to DCS (annunciator)
monitor
One Frequency Input
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 Operator Interface
FAULT ALARM PANEL
indicator indicator POWER
indicator
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READY DRIVER
AUX OIL ONLINE
(to run) RUN
PUMP indicator
indicator indicator
RUN

AUX OIL
PUMP
MODE

LOAD MODE
selector

RESET START E-STOP

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 Operator Interface Terminal
• Compressor monitoring
diagram
• Alarming (visual and
audible)
• Event and data logging
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• Real-time trending
• Control loop tuning
• Configuration and system
diagnostics
• Remote network and web
data access

•Two-level security
•Multi-lingual support
•Sunlight Viewable (outdoors) option available

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 Remote Access to data and
HMI screens
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 Air Miser Panel Installed
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 Air Miser Panel Installed
© 2007 Compressor Controls Corporation. All rights reserved.

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 Air Miser®ML Master Control Panel

Purpose-built for facilitating a single

pressure/flow set point control for
compressor network and load-sharing
between the compressors
© 2007 Compressor Controls Corporation. All rights reserved.

Provides optional compressor network

capacity management (sequencing) and
letdown valve control

In the future will have optional

functional modules for reciprocating
and rotary screw compressor control

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 Air Miser®ML Master
Control Panel Hardware

NEMA 4 enclosure
System health indicators
© 2007 Compressor Controls Corporation. All rights reserved.

8” VGA Touch Screen

Operator Interface
Terminal with Pointing
Device

32” x 24 “ x 10”
800 mm x 600 mm x 250 mm

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 Master Overview Screen
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 Compressor Network Setup
Screen
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 TL Panel HW Options (add-ons)

Panel space heater with

fan and thermostat

Panel cooler with thermostat

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Three (3) Vibration

Transmitters

Analog input expansion package =

nine (9) analog input modules +
control functions

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 TL and ML panel options
Option 1. Bundle of
– 10” TFT VGA Operator Interface Terminal with
– 100 W 24 Vdc power supply
© 2007 Compressor Controls Corporation. All rights reserved.

8” (Standard) 10” (Optional)

Sunlight viewable
with UV protection

Option 2. Serial-to-fiber converters for

controller network and DCS comms

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 Air Miser®TL
Vibration Monitoring
• VMIP Package Includes
– Three loop-powered vibration
transmitters (installed as a panel
option)
• Alarm and trip limits processed
by Air Miser Logic Controller
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• Optional vibration probe

replacement kit available
• Converts electrical signal from
an eddy current transducer to a
4-20 maDC current signal
proportional to vibration

• Air Miser also renders hardwired

interface with a 3-rd party
vibration monitor, such as
Bently Nevada
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 Optional Instrument Packages
• Cover 10 out of 13 analog inputs
in a basic I/O set
– TEIP = Four(4) Pt100 RTD’s
– PTIP = Five(5) Fast Response
Analog Pressure Transmitters
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– WTIP = One (1) Fast Response Watt

transducer
• Installed outside of the panel
RTD

WATT
Pressure Transmitters Diff. Pressure Transmitters Transducer
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 Optional Value Packages

MMVP= Motor Monitoring = Motor Winding + Motor

Bearing Temp

FEVP= Flow and Efficiency = Flow DP + Inlet Air Temp +

© 2007 Compressor Controls Corporation. All rights reserved.

Cooling Water Temp + Compressor Discharge Temp *

FMVP= Filter Monitoring = Inlet Air Filer + Oil Filter *

FMVP = + +

* Value Pack = Instruments + AI Modules + Functions

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 Flow & Efficiency Value Package

Always needed on a turbine-driven

compressor, otherwise when compressor flow
measurement is required or available
© 2007 Compressor Controls Corporation. All rights reserved.

Flow-based surge protection

Calculate compressor mass flow

Calculate compressor efficiency for

performance benchmarking
(motor-driven only)

Makes unit controls ready for compressor

network capacity management
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 Air Miser®System Tools

• Configurator with
pre-engineered
configuration view
© 2007 Compressor Controls Corporation. All rights reserved.

tabs

• Recorder with fixed

templates (to be
done)

• OPC servers

• Web server
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 PLC Vs CCC
• PLC Proponents:
–Create an image for a CCC
proprietary controller as a
“Black Box”, hard to understand
© 2007 Compressor Controls Corporation. All rights reserved.

and maintain, especially when

service personnel changes
frequently

–Sell on availability of PLC

components and huge job
market familiar with generic
PLCs
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 CCC Vs PLC
1. Air Miser is a purpose-built controller that already has
all control functions debugged and ready to use
2. Air Miser uses the same IEC-61131 as do all PLCs,
making understanding of programs not a more difficult
task than understanding of PLC programs
3. CCC programs are maintained by the same software
© 2007 Compressor Controls Corporation. All rights reserved.

designers who understand turbomachinery while PLC

programs are designed by random people
4. CCC guarantees lifetime support of its products while
PLC proponents shift the burden of support to
customers as they cannot provide adequate support
themselves (too costly)
5. CCC offers good parts management program making
replacement availability an easy task
6. CCC offers professional training and teaches how to
make use of the control system versus how to program
a PLC. Web-enabled training helps dealing with
turnover at minimum costs
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 Air Miser Vs PLC (summary)
CCC Air Miser 3rd party PLC
Controller HW and SW HW may have limitations
Purpose-built integrated
have inherent integration to run certain SW
platform
in the design applications reliably

I/O modules with galvanic Standard. Improve HW Isolated I/O modules are
isolation reliability and avaialblity very expensive
© 2007 Compressor Controls Corporation. All rights reserved.

CCC’s 30+ years of Typically no deep

Proven turbomachinery
leadership in the knowledge of
control applications
industry turbomachinery controls
Lots of time put in
Fully integrated reliable Typically will use the
quality component
control panel solutions cheapest components
selection and integration
Your confidence that Small integrator firms
Solid R&D and
this technology and its may dissolve as quickly
Engineering Bases
support will last as form
Field engineers with an Hassle-free, effective Limited or no exposure
average 5 to 10 years of resolution of the field to turbomachinery
experience problems controls real problems
We are interested that Integrators are
Professional trainers you understand as much interested to keep it all
as possible to themselves
Variety of ways to obtain
Customer care and tech May depend on a single
expert level help from
support person being available
many people

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 Bottom Line: Why choose CCC?
• Experience You Can Rely On
– Proven turbomachinery control technology
– Best Qualified To Identify and Solve Your Controls
Problems
– Established R&D and engineering bases with
institutional knowledge
– 80 field service engineers worldwide with unprecedented
© 2007 Compressor Controls Corporation. All rights reserved.

level of expertise in solving turbomachinery control

problems
– Experienced tech support
– Professional trainers

• Competitive Advantage in providing

– Integrated control solution
– Better surge protection
– Real energy savings managing compressor networks
– High level of engineering expertise
– Strong after-sales support

• Success in providing superior solutions for

this type of machinery with Series 2/3/3+ Air
Miser controls (over 100 machines since
1985) This document contains confidential information
 Why choose CCC?

E n g in e e rin g
E x p e rtis e

H ig h
“ S o lv e T h e
T e c h n o lo g y
P ro b le m ”
© 2007 Compressor Controls Corporation. All rights reserved.

And
A ttitu d e
In n o v a tio n

C u s to m e r

P ro v e n
A fte r-S a le s
P u rp o s e -b u ilt
S u p p o rt
S o lu tio n s

F ie ld S e rv ic e

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 Summary of User Benefits
Reduced Lifecycle Maintenance Costs Through
Improved Reliability

Reduced Lifecycle Operational Costs

© 2007 Compressor Controls Corporation. All rights reserved.

Effective Surge Equidistant CNCM Header

Controls Load Sharing Management

Ease of Operation

Integrity of Machine Critical Data

Dependable Global Field Service and

Technical Support

Professional Training Services

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 Air Miser® Applications Technology
Pre-programmed Configurable Functions

CCC Proven Surge Protection Techniques

C
C Power-based or flow-based surge control
C
© 2007 Compressor Controls Corporation. All rights reserved.

Equidistant from surge load sharing

Load share any compressor makes
V Load share small and big machines
A
Load share power-based
Text
and flow-based units
L
U Control loop dynamic decoupling
E Compressor Network Capacity Management
S
Letdown station control
Driver sequencing and control of auxiliaries
Machine Protection (vibration, intercoolers, etc.)
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 © 2007 Compressor Controls Corporation. All rights reserved.

THANK YOU!

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