Cooling Controls

Pump systems account for a significant share of energy use in industrial, commercial and municipal facilities, yet many operate far from optimal performance. This article explains how pump system assessments identify hidden inefficiencies in pumps, controls, piping and operating strategies, often uncovering opportunities to reduce energy consumption by 20–50% while improving reliability. Through real-world examples and best practices, it shows why data-driven pump system optimization is essential for lowering total cost of ownership and achieving long-term sustainability goals.

Faced with the requirement for improved cooling, a blow molding plant chose to invest in a significant redesign of its cooling systems that combined two separate systems into a single, integrated system. The combined design leveraged the components to provide a more controlled, efficient system while also requiring less space than the alternative would have needed. 

Controlling cooling water flow is a critical element of high-performance cooling systems. Fortunately, pressure is a straightforward measurement that can be used as a cost-effective control input for flow control systems. Proper interpretation of pressure readings is required for accurate control at desired rates. This article covers pressure reading methods, control strategies and practical tips.

Machine cooling high temperature problems are unfortunately all-too common in industrial plants. While the initial suspect is always the heat exchanger, there are several other factors that can be the underlying cause. Important steps can be taken to minimize the potential for heat exchanger fouling, but when problems do occur, careful examination of the machine and the system can help identify the problem efficiently and with minimal wasted effort.

Using a combination of predictive analysis and historical information helps companies make sound decisions relating to CUP operations. Ever-changing loads, weather and utility prices combine with hundreds of components that all impact energy efficiency. While previous strategies focused on individualized equipment efficiency and automation, CUP optimization considers the complete system. 

This article explores the distinction between standard system controls and holistic controls for highly efficient process cooling systems. Examples of high performance controls features and implementations are provided, and screening questions are listed for initial investigation of existing system and potential new systems.

Process cooling systems are mandatory components of the production infrastructure in many plants. System efficiency is second only to operational performance (i.e. meeting the process requirements) in the design and operation of these systems, and many companies go to great lengths to attain system efficiency.  Many times, unfortunately, the actual system performance is well below the hoped for efficiency target.

This article will discuss the instrumentation typically found in cooling systems and other plant utility systems, what other instruments and gauges should be used, how the instrumentation should be used, and good maintenance practices for instrumentation.

Have you ever woken in the middle of the night in a cold sweat wondering if your plant is using more energy than it should, putting you at a disadvantage as compared to your competition? Even if your energy monitoring or energy management system is in place you may not have the required insight to improve your performance and keep you competitive.

Penn State Health Milton S. Hershey Medical Center, Hershey Pa., is all about energy and resource efficiencies, which is why it adopted a new approach to managing its chilled water operation. The approach, which revolves around a software and analytics platform used to optimize three chiller plants in addition to various equipment upgrades, has allowed it to save 4.16 GWh/yr in electrical energy consumption – and shave $300,000 off of its annual electrical costs. With an incentive from the local utility of $415,799, the multi-phased initiative achieved a payback of 4.3 years.