Performance Monitoring for Chiller Efficiency Optimization

Chillers are high energy consumers and over 95% of the chillers waste 5-30% of the electricity on avoidable inefficiencies. Performance monitoring is the first step in chiller efficiency optimization.

Reduce your Chiller operating costs through optimization of energy efficiency, increased plant reliability and reduced equipment wear with this DENA endorsed solution (German Energy Agency) from our partners ClimaCheck AB in Sweden.

Energy Optimization

Identify saving opportunities and validate the saving measures taken to realize optimal Energy Efficiency. 

Predictive Maintenance

Identify emerging problems before they cause system failure and increase your energy bills with ClimaCheck.

system efficiency index

Use the SEI and the efficiencies of the sub-systems to flag deviations from optimal performance and allow for benchmarking across your chillers.

Worry-free chiller operations

The chiller is an expensive, sensitive, and complicated piece of equipment and its performance impacts people and processes. Chiller failure can have serious consequences. With real-time data, you can be confident in the fact that the chiller functions optimally :

  • The equipment runs in the most efficient way possible at all times and under any running conditions. 
  • Performance drift gets noticed and fixed immediately. 
  • Get early warnings about equipment issues that could lead to unscheduled stops (with their related panic, complaints, and other undesired consequences)
  • Meet the maintenance budget through predictive maintenance.  
  • Create energy consumption reports to meet ESG requirements.

How to get started with Chiller Performance Monitoring?

  • The system is affordable at a fraction of the savings that it will help you realize on energy and maintenance cost
  • Install it yourself or let us install it for you
  • Start monitoring straight away
  • Training and analysis on demand are available

Deal with the Challenges in Chiller Monitoring

The ClimaCheck system takes data via the internal method (measurement of the refrigeration cycle) and breaks down the overall efficiency to efficiencies of the 4 subsystems of the chiller. This method is highly accurate and allows you to:

  • Compare chillers of different brands and ages on a uniform standard
  • Evaluate chillers’ Coefficient of Performance (COP) at different running conditions (Heat Load and Ambient temperature)
  • Break away from the traditional (flow measurement-based) inaccurate and unreliable external measurement method.  

The uniformly applicable  System Efficiency Index (SEI) is calculated as realized COP as % of the Carnot COP (at prevailing running conditions). The SEI lets you compare all chillers at any time interval. 

Operational excellence in Chiller Operations through real-time operating data of your equipment

The BMS/MES does not provide these chiller data and analysis options that are essential for unbiased performance validation and benchmarking vs design and vendor data.
  • COP Overall efficiency of operation
  •  Subsystems efficiencies:
    • refrigerant cycle in the chiller
    • evaporator efficiency
    • condenser efficiency
    • compressor efficiency
  • Specific operating parameters such as:
    • Sub cool
    • Superheat
    • Heat Load
    • Water flow rates
    • Pressure levels, temperatures

Chiller Data Analysis and Reporting

The ClimaCheck chiller monitor provides the data for an ongoing improvement process that allows you to:

  • Optimize settings and control to maintain performance under varying running conditions (ambient temperature and heat load)
  • Create an Energy Signature and Energy Consumption Baseline for each unit
  • Flag performance drift in its earliest stage for immediate intervention and predictive maintenance.
  • Benchmark your chillers, and compare data across different chillers (any brand and age) through uniform SEI (System Efficiency Index)

The system can be installed within a day with immediate access to your data.

Chiller Efficiency Optimization Implies Dealing With Following Common Chiller Issues

Item Issue
Condenser Fouling and Corrosion
Refrigerant Shortage or overcharge
Flow balancing Too high or low on chilled
or cooling water
Compressor Wear and tear, damage
Controls Not properly commissioned
Components Changed or upgraded without
proper review
VFD Essential for capacity control but not correctly set up or used

Improvement Recommendations Sample Case 1

A 2-circuit water-cooled chiller (300 RT) was monitored. Although performing well in terms of cooling delivered, the analysis leads to the following recommendations: 

  • Avoid running at low loads
  • Keep the condenser clean from fouling
  • Decrease sensitivity of capacity controls
  • Increase chilled water temperature setpoint 

A series of simple adjustments on the Chiller sequencing in combination with smart usage of the chilled water storage and the introduction of a condenser cleaning regime allow for 30% energy saving on the chiller. 

Download

PDF file of this sample analysis
Download

Improvement Recommendations Sample Case 2

A 30-minute monitoring session on a chiller pointed out problems with compressor efficiency and oil cooling that dropped the System Efficiency 16% below its expected value. The owner called on the chiller manufacturer and the problems got remedied Free of Charge.  

Download

PDF file of this sample analysis
Download

Contact Request for Chiller Efficiency Optimization