Industrial Cooling System Design and Commissioning

No. A machine's electrical power is not the same as the heat load it transfers to the cooling system. Capacity calculations consider the actual process heat load, operating hours, simultaneity factor, target water temperature, ambient conditions and future capacity expansions together.

The most common reason is insufficient water flow reaching the process. Inadequate pump pressure, high piping losses, clogged filters, incorrect valve settings or hydraulic imbalance can prevent the required heat transfer even when the water temperature is suitable.

A buffer tank is required when system water volume is below 6–10 litres per kW, the process load changes rapidly, or the chiller's minimum capacity exceeds the instantaneous load. Tank volume is determined from equipment capacity, minimum run time, temperature tolerance and existing system water volume.

A primary-secondary system is preferred when the chiller circuit's minimum flow requirement needs to be separated from the variable-flow demand of the process circuits. It maintains safe flow through the chiller while allowing independent control according to production line requirements.

Yes, but available chiller capacity alone is not enough to determine suitability. Pumps, piping, headers, electrical infrastructure, tank volume and automation must also be checked. Assessment using site measurements is recommended before expanding capacity.

Yes. Capacity expansion, hydraulic modifications and automation work are performed independently of the installed equipment brand. The existing chiller's capacity at its actual operating point is determined through site measurements and used in the design.

For new facilities, work starts from drawings, equipment lists and process data. At existing facilities, a site survey is recommended because pump pressure, flow and temperature measurements substantially improve design accuracy. Surveys are planned within 24 hours in the Marmara Region and 48–72 hours elsewhere.

Full-capacity testing is performed if the facility can provide the design load. If the actual production load is unavailable, the system is tested at the attainable load level; pumping, control, alarm and capacity management functions are verified using different operating scenarios.

An approximate site COP can be calculated if adequate measurement equipment is available. Water flow, inlet and outlet temperatures and total equipment electrical consumption are measured simultaneously. Flow meter, temperature sensor and power analyser accuracy is essential for reliable results. Results are reported with the actual measurement conditions rather than EN 14511 rated conditions.

The main inputs are the equipment list, process heat loads, required water temperatures, operating hours, simultaneity, existing installation details, ambient conditions and future capacity plans. At existing facilities, pump pressure, flow and temperature measurements further improve design accuracy.