MANUFACTURING CUSTOM CONTROL SYSTEMS
FOR CENTRIFUGAL COMPRESSORS & BLOWERS
BLOWER & COMPRESSOR CONTROL PANELS
Efficient operation of any system is only as good as its control and integration to the process. Operating a very efficient blower or compressor inefficiently is very common when using 3rd party integrators. Lone Star offers a One Source Solution by offering not only local panels, but also including the process integration and a guaranteed pre-engineered and automated system.
Get reliability and greater efficiently with control panels designed for your operations.
Integrating the local blower and compressor control with the equipment package offers automation and control options as as well as protect your investment. Lone Star offers local control panels for Multistage Centrifugal, Integrally Geared Turbo Blower, Gearless Turbo Blower, Positive Displacement blowers and Centrifugal Compressors. Either simple protection or a completely automated controller communicating with a SCADA or DCS.
Lone Star can field service or retrofit your existing blower or compressor and process control no matter the brand or technology.
sLOC™ Local Control Panels
Automating your blower and compressor with a local control panel saves money through improved control functionality and protects your investment by monitoring critical inputs such as surge, vibration, or temperature. Local control panels can can also be provided with an integrated motor starter or variable frequency drive to save on installation and avoid integration issues. Systems are fully tested and warranted.
- Local Control Panel
- Centrifugal Compressors
- Geared Turbos
- Gearless Turbos
- Multistage Turbos
- Positive Displacement
- Centrifugal Compressor
- Pressure or Vacuum Air or Gas
- Can Combine with Motor Starter
- Panels Programmed and Manufactured at Lone Star
- Lifetime Warranty
- sLOC™ and sMAC™ Control uses a ramp control method to Operate with Control Variables
- Control Variables can be anything – Pressure, Dissolved Oxygen, The Price of Wheat in Madagascar
- No Flow Meter Needed
- Calculates Mass Flow more accurately and more reliably than a flow meter
- Uses Enthalpy equation at inlet and discharge to calculate flow with power and speed
- Entered into a 4th order polynomial equation of the performance curve of the blower and Centrifugal Compressor
sMAC™ Master Control Panels
FOR TOTAL SYSTEM RESPONSIBILITY
There are two levels of master control that a sMAC™ system can provide.
The first provides organizational control of the blowers and Centrifugal Compressors through sequencing. Sequencing automates which blowers turn on and off, modulates them to provide the total desired output, balances run hours between units, and can automatically restart a system after a power outage or unplanned shutdown. Many systems have difficulty operating multiple blowers on a common header and a master control panel can solve this through active control.
The second level can provide complete automation of your blower and Centrifugal Compressor process. Process control provides blower and Centrifugal Compressor sequencing, combined with the automation of process valves and instrumentation, and results in maximized energy savings.
PROCESSING & SEQUENCING CONTROL
Example of a 3 basin standard aeration application monitoring dissolved oxygen. Lone Star can provide a turn-key solution and provide all equipment shown.
Lone Star offers a complete solutions in providing a pre-engineered and automated process beyond local blower and compressor control.
Efficiency Optimization: sMAC™ sequencing can optimize your efficiency as blowers and centrifugal compressors are not equally efficient throughout their operating range. A smart sequencer does not move all blowers up and down together, but will operate blowers in their most efficient “sweet spot” and allow only one blower to be a variable trim unit.
Lone Star offers single point responsibility for the complete automation of your process including all hardware and on-site integration. The sMAC™ Process Controller can operate the blowers and centrifugal compressors to a set point such as flow or pressure, but also to process control variables such as off-gas, ammonia or dissolved oxygen at many points of use.
sMAC™ utilizes FOV – Fully Open Valve control uses flow set points to lower your header pressure to only what is required. Lower header pressure means lower power consumption! However, we can also provide traditional MOV – Mostly Open Valve type control using pressure set points.
Total System Responsibility means we will provide blowers and centrifugal compressors, local control panels, motor starters and drives, control valves, flow meters, and probes such as dissolved oxygen or ammonia sensors all integrated into a turn-key system. One source responsibility that offers both substantial energy savings and capital cost savings by adding a Master Control Panel to operate the entire system.
Sequencing: Operate multiple blowers and compressors more efficiently with a sequencing panel to always run blowers and centrifugal compressors at optimal power.
Process Control: Operate multiple points of use with flow control valves and flow meters to self-regulate to any variable input such as pressure, dissolved oxygen, or flow. The panel will automatically regulate the flow range of the blowers, centrifugal compressors, and control valves at each point of use to meet any set point.
Hybrid Systems: Integrate 2 blower and compressor technologies on the same common header to increase efficiency and lower capital costs.
We can control any blower and centrifugal compressor technology or a mix of technologies. Let Lone Star upgrade your existing system.
- Sequencing Multiple Blowers and Compressors
- Sequencing Mixed Technologies
- Process Control
- Aeration is our Specialty
- Multiple Control Variables
- Multiple Points of Use
Complete System Responsibility
Lower Pressure Means Lower Power Consumption
0.5 PSI Average Change is Nearly 5% Total Efficiency Gain
Even Actively Controlled Pressure Systems Keeps Artificially Higher Pressure to Adequately Control The Blowers and Compressors
sLINK™ Remote Monitoring & Services
- All standard sLOC™ and sMAC™ controllers include sLINK™ built in for remote monitoring and troubleshooting directly from the factory or connect to any cloud services
- Security: IEC 62443 is the worlds highest standard
- TOSIBOX® Allows user to control access
- Cloud Based Management – Connect to any Service
- Non-Proprietary and Open Architecture
- 24/7 Data Analysis available
- Access from any computer/smartphone/network
All standard sLOC™ and sMAC™ include PLCnext® processors.
Custom with proprietary PLC -Allen Bradley, Siemens, Modicon, etc…, can be quoted but will not get updates and have limited features
Non-Proprietary: Operates on Linux operating system so no software license is needed.
Communication: Connects to any known networks and proprietary PLC systems- http, https, FTP, OPC UA, SNTP, SNMP, SMTP, SQL, MySQL, DCP, etc.
PROFINET support and PROFICLOUD connection
Superior to any proprietary PLC system with faster processing power, memory and durability
Can be programmed in many common languages
sLOC™ and sMAC™ Control Systems
- For: Geared, Gearless, Multistage, Positive Displacement, Centrifugal Technology
- Pre-Engineered and Proven Protection
- Easy User Interface
- Retrofit Existing Blowers and Compressors
- Mass Flow Control Option
- Completely Automated or Simple Protection
- Direct Connection to Control Variable
MOTOR STARTERS AND DRIVES
Lone Star offers pre-engineered motor starters and drives to include with your blower and compressor system. These systems are plug compatible with our local control panels.
Our ONE SOURCE SOLUTION can bring added energy efficiency by matching the motor starter or drive to the exact needs of the motor and blower and compressor control system. The input/output will communicate to our local control system seamlessly and be pre-programmed and tested prior to shipment. No surprises on start up as Lone Star takes complete responsibility.
By offering the motor and the drive together the warranty will automatically be extended to 5 years for both products.
Save time and money by selecting from our standard packages that include the blower and centrifugal compressor control and starter all in one cabinet all pre-wired and ready for operation, or let us design to your specification.
- Soft Starter
- Solid State Starter
- Variable Frequency Drive
- Variable Torque or Constant Torque
- IEEE519 Compliance for Harmonic Mitigation
- UL Certified – All Components
- Enclosure Options: NEMA 1, NEMA 12, NEMA 3R, NEMA 4, NEMA 7
- Area Classifications: From Non Classified to Class 1 Division 1 or Zone 0 environments