Daily total energy vs outdoor average temperature
Baseline controlAI controlTransition day
Cooling plant case
Solar manufacturing cooling plant
A large industrial plant with low-temperature chillers, heat-recovery chillers, cooling towers, pumps, and plate heat exchangers was evaluated through comparable operating days.
- Average savings
- 21.29%
- 20-day comparable result
- 24.51%
- Major equipment
- 56 units
Average result across the comparable-day review.
Reported savings rate over the 20 operating-day comparison.
Chillers, towers, pumps, and plate heat exchangers in scope.
Plant profile
Large industrial cooling plant with heat recovery
The cooling source used centrifugal chillers. The system combined five low-temperature chillers including one standby unit, four heat-recovery centrifugal chillers with three duty and one standby unit, seventeen cooling towers, nine chilled-water pumps, nine condenser-water pumps, four heat-recovery pumps, four medium-temperature circulation pumps, and four plate heat exchangers.
Equipment
Major equipment
Cooling towers were connected in parallel. Chilled-water and condenser-water pumps used one-to-one pairing with chillers, while heat-recovery pumps were connected in parallel.
| Equipment | Quantity | Specification | Status |
|---|---|---|---|
| Low-temperature centrifugal chillers | 3 | 8791 kW cooling capacity / 1527 kW power / High-voltage supply / 0.61 kW/ton rated efficiency / Two fixed-speed, one variable-speed | Installed low-temperature group |
| Low-temperature centrifugal chiller | 1 | 7032 kW cooling capacity / 1229 kW power / High-voltage supply / 0.61 kW/ton rated efficiency | Installed low-temperature group |
| Low-temperature centrifugal chiller | 1 | 4220 kW cooling capacity / 725.2 kW power / High-voltage supply / 0.60 kW/ton rated efficiency | Standby included in low-temperature group |
| Heat-recovery centrifugal chillers | 4 | 8791 kW cooling capacity / 1464 kW cooling power / 10253 kW heating capacity / 1465 kW heating power / High-voltage supply / 0.59 kW/ton cooling / 0.59 kW/ton heating rated efficiency | 3 duty / 1 standby |
| Chilled-water pumps | 7 | 1410 m³/h flow / 47.5 m head / 250 kW / Integrated VFD | One-to-one chiller pairing |
| Chilled-water pump | 1 | 1200 m³/h flow / 50 m head / 220 kW / Integrated VFD | One-to-one chiller pairing |
| Chilled-water pump | 1 | 720 m³/h flow / 50 m head / 160 kW / Integrated VFD | One-to-one chiller pairing |
| Heat-recovery pumps | 4 | 1410 m³/h flow / 47.5 m head / 250 kW / Integrated VFD | Parallel connection |
| Medium-temperature circulation pumps | 4 | 650 m³/h flow / 48 m head / 132 kW / Integrated VFD | Included in plant scope |
| Cooling towers | 17 | Dual-speed fan / 30 kW / 22 kW | Parallel connection |
| Condenser-water pumps | 9 | 1900 m³/h flow / 28 m head / 185 kW / Integrated VFD | One-to-one chiller pairing |
| Plate heat exchangers | 4 | Included in heat-exchange plant scope | Included in plant scope |
Evaluation scope
Evaluation scope
- Comparison method
- Comparable-day analysis.
- Matching variables
- Average dry-bulb temperature, average wet-bulb temperature, production output, and average load.
- Operating window
- Twenty operating days were included in the comparable-day review.
Calculation detail
Matched-day energy-savings calculation
- Comparable-day basis
- Days matched by weather, production output, and average load.
- Matched-day pair
- Jun 20 baseline operation compared with Jul 13 AI operation.
- Baseline-day total energy
- 102,799.1 kWh
- AI-day total energy
- 82,833.7 kWh
- Matched-day energy savings
- 19.42%
- 20-day energy savings
- 491,304 kWh
- 20-day average plant efficiency improvement
- 21.29%
- 1. Comparable days were matched by weather, production output, and average load.
- 2. Jun 20 baseline and Jul 13 AI operation form the highlighted matched-day pair.
- 3. Matched-day energy savings = (102,799.1 - 82,833.7) / 102,799.1 x 100% = 19.42%.
- 4. The 20-day operating window reports 491,304 kWh measured energy savings.
- 5. The 20-day average plant efficiency improvement is reported as 21.29%.
Case result
Matched-day energy savings
=Baseline-day total energy-AI-day total energyBaseline-day total energy*100%
=102,799.1-82,833.7102,799.1*100%
=19.42%
Daily operating data
Daily operating data
The daily record includes chiller, pump, tower, total energy, dry-bulb temperature, wet-bulb temperature, production output, average load, and plant efficiency. Jul 15 is retained as a production-only partial record and excluded from the scatter plot.
| Mode | Date | Chiller kWh | Chilled-water pump kWh | Condenser-water pump kWh | Cooling tower kWh | Total energy kWh | Outdoor average temp C | Average wet-bulb temp C | Production output | Average load | Plant efficiency kW/ton |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Baseline control | Jun 20 | 75070.90 | 9583.50 | 8429.80 | 9714.90 | 102799 | 29.92 | 24.52 | 688854 | 13045.0 | 1.15 |
| Baseline control | Jun 21 | 76447.50 | 9467.60 | 8271.50 | 9957.60 | 104144 | 26.32 | 25.44 | 571028 | 12933.0 | 1.18 |
| Baseline control | Jun 22 | 73883.40 | 9225.10 | 7455.20 | 9858.10 | 100422 | 28.85 | 24.90 | 524893 | 12680.0 | 1.15 |
| Baseline control | Jun 23 | 73952.90 | 8472.80 | 7017.60 | 10090.00 | 99533 | 29.57 | 24.35 | 534134 | 13445.0 | 1.12 |
| Baseline control | Jun 24 | 70409.30 | 8361.50 | 7082.60 | 9211.30 | 95065 | 28.24 | 24.05 | 506286 | 12298.0 | 1.17 |
| AI control | Jun 25 | 56407.80 | 4672.70 | 3709.50 | 7058.60 | 71849 | 27.94 | 22.77 | 382753 | 11638.0 | 0.89 |
| AI control | Jun 26 | 54539.60 | 4510.40 | 3662.40 | 6480.60 | 69193 | 28.37 | 21.84 | 549494 | 11605.0 | 0.86 |
| AI control | Jun 27 | 66422.50 | 4832.90 | 4801.30 | 8020.80 | 84078 | 28.10 | 22.26 | 693348 | 12228.0 | 1.00 |
| AI control | Jun 28 | 72261.40 | 3256.50 | 5137.20 | 8838.50 | 89494 | 25.40 | 23.63 | 1144404 | 14007.0 | 0.92 |
| AI control | Jun 29 | 79760.40 | 5428.10 | 3904.60 | 7252.20 | 96345 | 26.96 | 24.50 | 1221449 | 14769.0 | 0.94 |
| AI control | Jun 30 | 85812.20 | 5596.50 | 5596.50 | 8331.60 | 105189 | 29.86 | 25.52 | 1192267 | 15525.0 | 0.97 |
| AI control | Jul 1 | 79121.00 | 5187.50 | 4399.50 | 6976.00 | 95684 | 27.94 | 24.19 | 1269512 | 14646.0 | 0.97 |
| AI control | Jul 2 | 53493.50 | 5149.70 | 4369.40 | 6976.00 | 69989 | 26.23 | 23.00 | 1113689 | 13940.0 | 0.92 |
| AI control | Jul 3 | 94986.00 | 6039.00 | 5932.00 | 7987.00 | 114944 | 29.42 | 25.12 | 1230929 | 17350.0 | 0.95 |
| AI control | Jul 4 | 98116.00 | 6411.00 | 7840.00 | 5775.00 | 118145 | 27.90 | 25.45 | 1240557 | 18045.0 | 0.95 |
| AI control | Jul 5 | 119534.00 | 7902.50 | 5574.90 | 9502.50 | 142514 | 32.62 | 26.91 | 1303832 | 20199.0 | 1.02 |
| AI control | Jul 6 | 119640.40 | 7628.10 | 6410.20 | 8428.20 | 142107 | 31.69 | 27.24 | 1300464 | 20256.0 | 1.02 |
| AI control | Jul 7 | 125835.00 | 7264.00 | 6160.00 | 5853.80 | 145113 | 33.63 | 27.50 | 1305833 | 20824.0 | 1.00 |
| AI control | Jul 8 | 126807.50 | 7072.60 | 6539.20 | 5708.20 | 146128 | 32.55 | 27.59 | 1414561 | 20974.0 | 1.00 |
| AI control | Jul 9 | 102834.10 | 6083.20 | 6083.20 | 5296.10 | 120297 | 26.88 | 25.22 | 1307950 | 18145.0 | 0.95 |
| AI control | Jul 10 | 87367.80 | 5571.90 | 3722.30 | 5203.30 | 101865 | 25.75 | 23.94 | 1010981 | 16011.0 | 0.93 |
| AI control | Jul 11 | 69052.00 | 3093.00 | 5083.00 | 3843.00 | 81071 | 25.38 | 23.18 | 536456 | 13644.0 | 0.90 |
| AI control | Jul 12 | 70339.00 | 3141.40 | 6052.00 | 5265.00 | 84797 | 26.40 | 25.09 | 384039 | 13541.0 | 0.93 |
| AI control | Jul 13 | 69491.00 | 2999.60 | 5468.80 | 4874.30 | 82834 | 28.65 | 25.87 | 289535 | 13327.0 | 0.92 |
| AI control | Jul 14 | 63633.00 | 3599.10 | 3931.00 | 5559.00 | 76722 | 26.55 | 25.47 | 210710 | 11368.4 | 1.02 |
| Transition day | Jul 15 | 189780 |
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