Industrial Cooling Energy Analysis and System Optimisation

Not always. The displayed value represents only the chiller's own consumption or estimated performance calculated by the controller. Actual system efficiency is determined using measured water flow, temperature difference and simultaneous electrical consumption. Pumps and auxiliary equipment are assessed separately.

Most measurements are taken while normal production continues; observing the system under actual load provides more meaningful results. If sensor installation, electrical panel measurements or flow meter connections require a brief controlled intervention, the work is planned with the facility. Clamp-on flow meters and surface temperature sensors do not require modifications to the piping.

The required duration depends on load variability. For a facility operating at a constant load, 2–3 days of measurements may be sufficient; systems that vary with shifts, production volumes and outdoor temperature are monitored over a representative period of 7–14 days. The measurement duration is agreed at the start of the work.

Facilities operate at 30–70% load for much of the year; full-load COP does not indicate consumption in this range. Part-load indicators represent annual consumption and equipment sequencing decisions more accurately than full-load values.

No. Savings potential depends on the system curve, control method and variable-flow requirements. Minimum flow requirements for evaporators and process equipment must also be maintained. A drive installation is assessed together with hydraulic analysis and an appropriate control strategy.

It does in suitable applications; each 1 °C increase reduces compressor consumption by roughly 2–3%. A higher evaporation temperature improves compressor operating conditions. However, the setpoint is not changed without checking product quality, cycle time, condensation risk and process temperature tolerance.

Free cooling is particularly advantageous at facilities that need cooling throughout the year and operate with relatively high water temperatures. Suitability is calculated using hourly weather data, taking into account the climate region, target water temperature, operating hours and existing mechanical infrastructure.

A facility energy audit covers the entire site, including boilers, compressed air, lighting and motors. Chiller energy analysis examines only the cooling system through detailed measurements and provides input for the cooling section of the wider audit.

Yes. The energy baseline, energy performance indicator (EnPI) definition and IPMVP-compliant measurement and verification plan can be incorporated directly into ISO 50001 documentation.

A performance baseline is established before implementation. Measurements are repeated afterwards under comparable production loads, outdoor temperatures and water temperatures. Changes in cooling load or production volume are taken into account in the comparison.

The main inputs are the equipment list, operating hours, electrical consumption, target water temperatures, production schedule, pump details, automation records and previous energy bills. If flow, temperature and power measurements are already available, the analysis scope can be established more quickly.