Controlling a Multiple Compressor Installation Using Integrated Compressor Control

What is Integrated Compressor Control?

Integrated Compressor Control (ICC) is a coordinated sequencing feature that allows multiple compressors to maintain a constant system pressure while ensuring maximum energy efficiency and minimal blow-off. 

When using the ICC feature, compressors are connected through an integrated Peer-to-Peer (P2P) network. The P2P network, coupled with the ICC sequencing software included in each of the local control panels, allows users to select any of the networked compressors as the master controller, thus creating redundancy and reducing cost by eliminating the need for a separate master controller. 

How Does ICC Work and What Does It Deliver?

At the heart of ICC is a master sequencing logic that dynamically manages:

• Starts and stops
• Load and unload transitions
• Inlet valve modulation
• Blow-off and turndown optimization

Once a compressor is assigned as the master, it evaluates plant demand in real time and modulates inlet and unloading valves across all networked compressors. This keeps operating units within their most efficient performance bands and reduces throttling inefficiencies.
 

Energy Savings and Blow-Off Reduction

There are several benefits to utilizing ICC within a group of compressors, but one of the main benefits is that ICC can eliminate unnecessary blow-off by throttling (closing) the inlet valves of all operating compressors until maximum system turndown is achieved. Once all operating compressors have reached maximum turndown, the ICC master can assign a single compressor to blow off and shut down. This method of control will eliminate unnecessary and uncontrolled blow-off while ensuring that each compressor is operating at peak efficiency.
 

Advanced ICC Features Tailored for Complex Demand Profiles

Understanding that every system has its own requirements and compressor sequencing does not allow a one size fits all solution, FS-Elliott has developed the following features and functions within our ICC offering:

• Compressor (P2P) Networking - Up to six compressors can be connected in a coordinated network. Each HMI displays critical data from all units, supporting system wide visibility and control.
• ICC Master Control Architecture - Each compressor contains the master control logic. If the designated master is unavailable, the next priority controller automatically assumes control, preserving system sequence without interruption.
• Time Leveling Control - To balance run hours across compressors, ICC tracks individual service time. Units with the fewest hours receive lead priority, equalizing usage and extending fleet longevity.
• Lead/Lag Control - When multiple air compressors (two or more) are in operation, lead/lag control is used to ensure certain compressor(s) are in the lead (baseload), whereas other compressors act in a trim function (throttled).  
• Load Sharing - During load sharing control, the master controller steps in and ensures that the inlet valves of all compressors are throttled to the same percentage, and any required blow-off is achieved through a single trim compressor.  Each air compressor unit proportionately shares the load of the plant air system to further increase efficiency.

Operational Benefits of Integrated Compressor Control

• When implemented effectively, ICC delivers measurable operational improvements:
• Consistent system pressure with fewer fluctuations
• Reduced energy costs through coordinated sequencing
• Fewer hours at part load and reduced blow off
• Improved component life through balanced run time

Is ICC Right for Your Installation?

Consider ICC if your system meets one or more of the following conditions:

• You operate two or more compressors in parallel
• Your plant experiences variable system demand profiles
• You need to optimize energy usage across multiple machines
• You want to eliminate unnecessary blow off and throttling
• You seek redundancy and robust control logic without extra master controller hardware

ICC is especially effective in facilities with fluctuating demand cycles, such as manufacturing plants, process facilities, and heavy industrial environments.
 

Evaluate Your Control Strategy

Determining whether ICC is the optimal solution for your facility starts with a review of your current control architecture, demand patterns, and efficiency targets. FS‑Elliott’s team can help assess your system’s suitability for integrated control and recommend the best configuration to align with your performance goals.

For more information on ICC or other compressor control solutions, contact your authorized FS-Elliott Channel Partner.