Controls

CALMS CAL-PM-x EMCS is Energy Management Control System add-on for permanent monitoring CALMS devices.

EMCS - Energy Master Control System

• Often referred to as a system controller or “sequencer”- orchestrates control and monitoring of a multiple-compressor system
• Programmable Logic Controller (PLC) based
• Can only use available commands: Start/Stop, Load/Unload, %load with variable compressors or %IGV with centrifugal compressors
• Works with various compressor makes and models and types
• May incorporate production schedules and IO signals from production
• Can be integrated into plant SCADA systems
• Can control PFCs and SOV, AUX equipment
• Can help meet “IIoT” goals with remote monitoring
• GOALS
  • Specific efficiency (m3/min)/kW or (cfm /HP)
  • Specific energy or power (kWh/m3) or (kW/100cfm)
  • No unneeded compressor left running
  • Stable, acceptable system pressure

Features

• CALMS PM-X is a device that is installed in Compressed Air System room and gather data from all connected sensors and equipment and send it to CALMS web application through mobile network;
• Sending data packages every minute with sample rate 5 sec - scope function 1 sec;
• Control types of PM-X devices: PM-2 (up to two compressors), PM-4 ( up to 4 compressors), PM-8 ( up to 8 compressors)) PM-16;
• Many sensors (Pressure, Flow, Temperature, Vibration, Current, Power, Dewpoint, particles and other 4-20mA sensors) can be connected to device;
• Can read data from many different slave devices (MODBUS RTU, TCP, PROFIBUS, ADS, OPC. .);
• General alarm output–>Alarm relay output can be used for real time signaling;
• EMCS-Integrated system controller for regulation of compressors, dryers and all other CAS equipment;
• CAL-C-ON/OFF is a compressor interface module for ON/OFF or VSD compressors with integrated power analyser ( with 3 phase CTs)
• CFC (CALMS Pressure Flow Controller);
• SOV (Shut Off Valves);
• Flexible & Multiple devices for each compressor room connected to the same system
• Can be integrated into customer SCADA system;
• Automatic energy data analysis and reports
• 3G/4G communication
• Easy to use remote interface with remote access

Considerations

• Master controls won’t fix an otherwise broken system! Incorrect compressors size, system volume and distribution system must be adequate.
• Always start with an audit to evaluate the benefits of controls and get Functional Specification
• Over expectation - avg. gains 12%, but applicability rate is 20% - so potential contribution 2.4% (CAS in EU 2001)
• Consideration Risk - Will 10 minute of downtime offset 2 years of energy savings? (Reliability / Efficiency)
• Compressors modifications/repairs have been identified
• Buy where, from whom, DIY / standard products or custom design?
• A control specification and goals are needed

Technical data