Illustrative scenario

Chiller circuit leak isolated without a shutdown

Illustrative scenario, representative of common industrial IoT applications

WaterManufacturing: Automotive, Plastics & Rubber

Continuous monitoring helped identify and isolate a leaking cooling loop while the production line remained in operation.

An automotive factory

No client is named, no logo is shown and no figure here was measured at any site.

How it went.

Every study on this site runs the same four beats, in the same order.

  1. 01

    Alert

    A closed cooling loop was making up far more water than a closed loop should. Nobody knew which of several circuits was responsible.

  2. 02

    Cost

    1 loop isolated. Identified by sub-meter divergence, with no production stoppage.

  3. 03

    Fix

    Sub-meters on each cooling circuit's make-up line · Continuous differential comparison between circuits · Threshold alerting on make-up rate

  4. 04

    Restored

    One circuit named, isolated and repaired on a planned outage

In full.

Illustrative scenario, representative of common industrial IoT applications.

The problem

A closed cooling loop was making up far more water than a closed loop should. Nobody knew which of several circuits was responsible.

What would be installed

  • Sub-meters on each cooling circuit’s make-up line
  • Continuous differential comparison between circuits
  • Threshold alerting on make-up rate

What changes

Before: One aggregate make-up figure, four candidate circuits After: One circuit named, isolated and repaired on a planned outage

The number

1 loop isolated. Identified by sub-meter divergence, with no production stoppage. Illustrative scenario, not a client result. Figure is representative, not measured.

In one line

Sub-metering does not find leaks. It narrows them until the answer is obvious.

What the data looked like.

Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.

Chiller circuit leak isolated without a shutdown
MAKE-UP WATER BY CIRCUIT · 7 DAYS · 4-HOURLY

What changed.

Before

One aggregate make-up figure, four candidate circuits

After

One circuit named, isolated and repaired on a planned outage

1 loop

isolated

Identified by sub-meter divergence, with no production stoppage.

Source: Illustrative scenario, not a client result. Figure is representative, not measured.

Find out what’s hiding in your factory.

Every study on this site started with somebody walking a floor and asking what the numbers actually were. Our team will do the same on yours and tell you honestly what we find.

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