Keep it
simple
Last year I asked a chief engineer about his opinion of
my newsletters. He had replied that they held valuable information. However, it
would have been better if somebody would have been able to tell him how to use
this information to improve the efficiency of his plant.
Energy savings in industrial refrigeration is pretty
complicated, because of many variables. This is the reason that even if you have
information about energy savings, it is not easy to apply this information into
real life energy savings.
To
help companies to implement known information about energy savings, I started
the remote tuning up of refrigeration plants. After several years of extensive
research in energy efficiency in industrial refrigeration I have obtained
several models of refrigeration plant optimization. To apply these models to a
particular plant, we should input the variables of this plant and optimum set
points can be predicted. This approach does not require a visit to the
refrigeration plant and tuning up can be done remotely.
It
may look complicated but my goal is to keep it simple for end users. A similar
approach could be seen in IT technologies (computers). It is a complicated task
to create the software, but this software is user friendly and everybody can use
it.
What is needed for successful remote tuning
up?
1.
Knowledge of optimum set
points of the refrigeration plant.
2.
Knowledge of adjustment of
the refrigeration plant for these set points.
Based on the information about refrigeration plant
provided by the end user, a consultant is able to determine the optimum set
points for this refrigeration plant at current ambient conditions and gradual
adjustment of the plant can be done.
For
example. A refrigeration plant operates at
140 psig head pressure. The consultant determines that the
optimum set point, at current ambient conditions, is 100
psig. Step by step head pressure will be reduced to 100
psig
and the plant will be adjusted to this head pressure. Why
should this tuning up be done step by step?
1.
Significant change in head pressure
can compromise refrigeration plant operation (hot gas defrosting, liquid supply,
oil cooling, etc.). Small steps (10 psig
) will allow us to avoid
problems in plant operation, because the adjustment can be done in time.
2.
Significant change in head pressure
can be shocking for operating engineers. Somebody who has operated this plant at
140 psig
for many years could become confused if the head pressure
dramatically changes.
In
this tuning up, the consultant works as a guide for the chief engineer
(supervisor). This guide will advice the direction and the pace of the tuning
up. He will warn the chief engineer about road blocks ahead. The process of this
tuning up is pretty simple, if the consultant and chief engineer work together
as a team.
A major
advantage of the remote tuning up is that everybody can test it without even
investing a dollar, because the initial step of this tuning up is
free. It is not often that somebody will
be able to save you $10,000 - $40,000
of energy costs without any
investments.
To
maximize the efficiency of refrigeration plants, several approaches have to be
tested and the best one should be chosen.