Daily total energy vs outdoor average temperature
Baseline controlAI controlTransition day
Plant case
Solar manufacturing 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 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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