CASE54 · Manufacturing · Header-pressure control
Moving compressor pressure control from individual outlets to the common header
Common-header and critical end-use pressure measurements support integrated sequencing and staged pressure tests. The target is adequate process service with minimum system energy.
01 · CASE ANALYSIS
Choose the service-side control reference
Independent compressor discharge controls can interact without accurately representing production requirements. The source action changed the pressure sensing/control reference from individual compressors toward the common CDA header.
The starting point is the minimum pressure needed at the critical process use, not the compressor’s rated pressure.
02 · CASE ANALYSIS
Measure the pressure network
Align compressor discharge, header, branch and terminal pressure with airflow, unit power and loading/unloading.
Required header pressure is approximately critical end-use minimum pressure + distribution pressure drop + necessary operating margin. Investigate filters, dryers, piping and valves before using higher pressure to conceal losses.
| Aspect | Individual control | Header-based approach |
|---|---|---|
| Reference | Each discharge sensor | Common header plus critical end use |
| Control action | Separate load/unload decisions | Coordinated sequencing |
| Evaluation | Local pressure and machine state | Service stability and total specific energy |
03 · CASE ANALYSIS
Coordinate pressure and staging
Common pressure control and compressor dispatch are one system problem. Narrower stable pressure operation may reduce unnecessary loading/unloading while maintaining short-term demand response.
Do not transfer an absolute setpoint from another factory: terminal requirements, air quality and demand patterns differ.
04 · CASE ANALYSIS
Test in stages
Establish baseline service and total power, then adjust the setpoint gradually and wait for stabilization. Confirm the critical terminal pressure and process operation at each stage.
The source lists approximately KRW 230 million/year as an expected benefit for an item still in progress, not a completed independently measured saving.
| Measure | Acceptance question |
|---|---|
| Critical terminal pressure | Is the minimum process requirement maintained? |
| Header pressure and airflow | Is demand met with stable pressure? |
| Units and loading/unloading | Did control behavior improve? |
| System power and specific energy | Is total energy lower under comparable service? |
| Production | Are normal operation and quality maintained? |
05 · CASE ANALYSIS
M&V boundary
Compare total compressor electricity and specific energy under matched delivered-air volume, pressure requirements and production conditions. Keep dispatch, storage and distribution changes documented.
CASE52 concerns running-unit count; CASE54 concerns network pressure. Their interaction does not justify adding unrelated scenario savings.
APPLY TO YOUR SITE
Connect your operating data to an actionable energy strategy.
Discuss the measurement boundary, data quality, operating constraints and verification approach for your facility.
Discuss your project All English cases