OBJECTIVE

To identify operational inefficiencies in the cooling system of an automotive plant, improve system reliability, and reduce energy consumption without compromising production quality.

APPROACH AND METHODOLOGY

Perform a specialized energy audit, focusing on an in-depth analysis of the cooling systems that support thermally sensitive processes in the industrial plant.

• • The audit was conducted by Articae over a period of two and a half weeks.
  • Use of the PilotE2 Iceberg advanced monitoring system.
  • Distributed instrumentation with temperature and pressure sensors, network analyzers, and dynamic data capture from the compressors.
  • Monitoring of more than 20 critical variables per chiller.
  • Calculation and performance under different load conditions.

Identified problems

• • Excessive starts and stops (up to 87 daily cycles per compressor), with ON/OFF logic without dynamic control.
  • High condensing pressures, reducing efficiency.
  • Superheating >12°C in several circuits.
  • Imbalance in the distribution of operating power between compressors.
  • Absence of variable frequency drives and lack of adaptive control strategy.

Results Obtained

• • Overall system SEER: 5.47, with room for improvement.
  • Potential reduction in power consumption >20%.
  • Estimated increase in compressor lifespan >30%.
  • Return on investment <3 years if the recommended improvements are implemented.

We would especially like to highlight the active involvement and collaboration of SEGUAS, whose commitment to continuous improvement and energy efficiency has been key to the success of this audit. Their strategic vision has facilitated the identification of real optimization opportunities with a direct impact on the performance and sustainability of the thermal system.