Master Air Control

Great Savings and Performance

Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com

 The Need for Master Air Control (MAC)

In every industry, the compressed air demand of the plant keeps fluctuating
constantly due to intermittent use of pneumatic equipment. Generally industries
end up with losses due to inefficiencies and higher energy bills. In this situation, a
proper balance between supply and demand of compressed air is required.
Master Air The Master Air Control addresses this problem by ensuring a steady delivery of

Control pressure to the consumption side irrespective of the fluctuations in demand.

MAC introduces a differential pressure between the receiver and itself and thus
creates a useful high-pressure storage. This helps in isolating the compressors
from demand surges.

Peaks in demand are handled by the MAC, rather than being directed towards the
compressors. This allows compressors to run longer on no-load, and as a result,
the mass of air decreases and compressor load cycles are reduced.

This decrease in compressor load cycles is directly proportional to the decrease in

energy consumed by the compressors.

Thus, by installing the MAC, compressors are protected from artificial demand and
they have to cater only to base demand, resulting in savings on compressed air
energy consumption.
The Forbes Marshall Master Air
Control (MAC) is an energy saving Furthermore, a constant pressure is now delivered to all plants and pneumatic
control system, which actively helps equipment, helping better quality and productivity in production processes.
you control the balance across the
demand and supply sides. It acts as a
buffer between the compressors and
the demand fluctuations due to
artificial demand on the consumption
side. Installation of the MAC helps
reduce the excess load on
compressors caused by artificial
demand, thereby reducing the energy
consumed.
The MAC finds applications in all
industries, including automobiles, Master Air Control in a compressed air system
cement, power, textiles, iron & steel
and paper.

Supply Demand
Typical Compressed Air Usage

Normal Leaks
Production 25%
50%

Artificial
Demand
Inappropriate 10%
use 15%

Pressure Profiles With and Without the MAC

Pressure Delivered To Plant

Before MAC
PSI
100

80

After MAC

Features Benefits
HMI with touch screen, clear and bright display, ideal Saves energy consumed by air compressors by cutting
for use in plants. artificial demand for air

History and trending feature Reduction in compressor loading and induces higher
unloading period
Failsafe operation
Separates compressors from demand side peaks and
Accurate pressure control lows, thus reduces compressor cycling to minimal

Highly responsive to fine changes in demand Consistent air pressure delivery to demand side

User-friendly HMI interface Enhanced useful air storage capacity

PID tuning assisted with parameter value trends Accommodates any make of compressor

Provision to set limits for alarms, flow etc Demand reduction tends to reduce leakages in plant

Provision to add flow consumption input via a flow

meter

Shift/time based set points can be added

Optional connectivity to PC available

Specifications

Make Forbes Marshall Master Air Control

Rated for 150lb ANSI
Power supply 230 V AC, single phase, 50 Hz
Pressure set point resolution 0.01 bar
Pressure control range ± 0.01 bar
Feedback control system Micro-controller based PID control with closed loop
feedback control system
Inlet air temperature to MAC 55ºC
Ambient operating conditions 0ºC – 55ºC
Pressure difference across the MAC at rated flow should be 0.2 bar
Inlet and outlet connections From left with ANSI flange

Better Savings, Better Efficiency

Average Energy Consumption (kWH)

8000

7000

6000

5000

4000
Without MAC With MAC
Energy consumed = 5510 kWH/day Energy consumed = 4400 kWH/day
3000
Energy saved = 1110 kWH/day
2000
Energy cost saving = Rs. 23 Lakhs per year (20%) = 34460 USD
1000
kWH/Day Without MAC With MAC

Opp 106th Milestone B-85, Phase II, Chakan Indl Area A-34/35, MIDC H Block
Bombay Poona Road Sawardari, Chakan, Tal. Khed Pimpri, Pune - 411 018. INDIA.
Kasarwadi, Pune - 411 034. INDIA Dist. Pune - 410 501. INDIA Tel : 91(0)20-27442020, 39851199
Tel : 91(0)20-27145595, 39858555 Tel : 91(0)2135-393400 Fax : 91(0)20-27442040
Forbes Marshall Fax : 91(0)20-27147413
Krohne Marshall CIN No.: U28996PN1985PTC037806
Forbes Marshall Arca Email : airaudits@forbesmarshall.com, ccmidc@forbesmarshall.com www.forbesmarshall.com
Codel International © All rights reserved. Any reproduction or distribution in part or as a whole without written permission of Forbes Marshall Pvt Ltd, its associate
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Information, designs or specifications in this document are subject to change without notice. Responsibility for suitability, selection, installation, use,
Forbes Vyncke operation or maintenance of the product(s) rests solely with the purchaser and/or user. The contents of this document are presented for informational
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