Illustrative scenario
Refrigeration condenser fouling detection
Illustrative scenario, representative of common industrial IoT applications
Cooling towersEnergy & electricityFood & Beverage ProcessingControlled Environment Agriculture (Greenhouses)
Head pressure rose while load remained constant, revealing condenser fouling and quantifying its energy cost.
A food storage and processing site
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
A fouling condenser makes the compressor work harder for the same cooling. It never trips an alarm. It just quietly raises the electricity bill.
02
Cost
Head pressure vs. load. The ratio drifts long before the system trips on high pressure.
03
Fix
Head pressure transducer on the refrigeration circuit · Compressor current monitoring · Ratio trending with a cleaning threshold
04
Restored
A cleaning schedule based on the measured penalty
In full.
Illustrative scenario, representative of common industrial IoT applications.
The problem
A fouling condenser makes the compressor work harder for the same cooling. It never trips an alarm. It just quietly raises the electricity bill.
What would be installed
- Head pressure transducer on the refrigeration circuit
- Compressor current monitoring
- Ratio trending with a cleaning threshold
What changes
Before: A cleaning schedule based on the calendar After: A cleaning schedule based on the measured penalty
The number
Head pressure vs. load. The ratio drifts long before the system trips on high pressure. Illustrative scenario, not a client result. Figure is representative, not measured.
In one line
Maintenance on condition rather than on the calendar, with a number attached to the delay.
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.
| Interval | Rack 1 (kPa/kW) |
|---|---|
| D1 | 13 |
| D2 | 12 |
| D3 | 12 |
| D4 | 12 |
| D5 | 13 |
| D6 | 13 |
| D7 | 12 |
| D8 | 13 |
| D9 | 13 |
| D10 | 13 |
| D11 | 13 |
| D12 | 13 |
| D13 | 13 |
| D14 | 13 |
| D15 | 13 |
| D16 | 13 |
| D17 | 13 |
| D18 | 13 |
| D19 | 13 |
| D20 | 13 |
| D21 | 13 |
| D22 | 13 |
| D23 | 13 |
| D24 | 13 |
| D25 | 13 |
| D26 | 13 |
| D27 | 13 |
| D28 | 13 |
| D29 | 13 |
| D30 | 13 |
| D31 | 13 |
| D32 | 13 |
| D33 | 13 |
| D34 | 14 |
| D35 | 13 |
| D36 | 13 |
| D37 | 13 |
| D38 | 14 |
| D39 | 14 |
| D40 | 14 |
| D41 | 14 |
| D42 | 14 |
| D43 | 14 |
| D44 | 14 |
| D45 | 14 |
| D46 | 14 |
| D47 | 14 |
| D48 | 14 |
| D49 | 14 |
| D50 | 14 |
| D51 | 14 |
| D52 | 14 |
| D53 | 14 |
| D54 | 14 |
| D55 | 14 |
| D56 | 14 |
| D57 | 14 |
| D58 | 14 |
| D59 | 14 |
| D60 | 14 |
| D61 | 14 |
| D62 | 14 |
| D63 | 14 |
| D64 | 14 |
| D65 | 14 |
| D66 | 15 |
| D67 | 14 |
| D68 | 14 |
| D69 | 14 |
| D70 | 15 |
| D71 | 15 |
| D72 | 15 |
| D73 | 15 |
| D74 | 15 |
| D75 | 15 |
| D76 | 15 |
| D77 | 15 |
| D78 | 15 |
| D79 | 15 |
| D80 | 15 |
| D81 | 15 |
| D82 | 15 |
| D83 | 15 |
| D84 | 15 |
| D85 | 15 |
| D86 | 15 |
| D87 | 15 |
| D88 | 15 |
| D89 | 15 |
| D90 | 15 |
| Before | A cleaning schedule based on the calendar |
|---|---|
| After | A cleaning schedule based on the measured penalty |
What changed.
Before
A cleaning schedule based on the calendar
After
A cleaning schedule based on the measured penalty
Head pressure
vs. load
The ratio drifts long before the system trips on high pressure.
Source: Illustrative scenario, not a client result. Figure is representative, not measured.
Where to go next.
The sector, the sibling studies, and the calculator that runs this same arithmetic on your own numbers.
Cooling towersWaterManufacturing: Automotive, Plastics & RubberBuilding Materials, Concrete & Aggregates
Cooling tower blowdown optimization
A plastics manufacturing factory
Blowdown was controlled by a timer rather than conductivity, causing usable water to be discharged unnecessarily.
1 setpointchanged
Energy & electricityBulk Handling & Rail Logistics
Night setback that never happened
A distribution warehouse
The overnight setback had silently stopped working, and it was worth about a third of the load.
~35%of overnight electrical load
Energy & electricityManufacturing: Automotive, Plastics & Rubber
Three factories, one unit of production, one outlier
A manufacturer with three factories
Same product, same equipment, and one factory used about 40% more energy per unit.
~40%more energy per unit
Find out what’s hiding in your factory.
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