6 Steps to Maximizing Efficiency with EffTrack
Step 1 - Set Up Chiller Design Data
The chiller full load design specifications along with other performance data are entered into the EffTrack chiller setup. This information can typically be collected at the facility or from the chiller manufacturer.
Step 2 - EffTrack Collects Chiller Operating Data
EffTrack automatically collects operating data every hour and uploads the data to the EffTrack servers for processing.
Accurate data is critical for producing reliable performance analysis, diagnostics and cost reporting. Industrial quality sensors* including evaporator and condenser water temperatures, refrigerant pressures, water flows, amps, volts and power factor are required.
Other options for integrating with a BAS and collecting the operating data may be available pending a plant survey. EffTrack provides the flexibility to accommodate virtually any IT security requirement.
A graphic interface is included with the Data Acquisition Board that allows operators to view real-time operating data from the plant computer and remote locations.
* EffTrack industrial sensors have a 5-year manufacturer warranty.
Step 3 - EffTrack Processes the Data Using Proprietary Calculated Part Load Value (CPLV) and Diagnostics Software.
EffTrack utilizes a combination of the full load design specifications and other data to create a CPLV efficiency profile, which is the foundation for cost reporting and diagnostics.
The actual chiller operating data is compared against the CPLV profile to measure operating efficiency under ALL operating conditions (not just full load).
Diagnostics determines the cause of inefficiency between the CPLV and Actual efficiency.
Step 4 - EffTrack Develops Operational Reports
The Daily Report
This report provides comprehensive analysis and statistics of daily chiller performance derived from processing the operating data.
The Calendar Report
The Calendar is the archive of the Daily Reports. Clicking on any day accesses the Daily Report.
The Monthly Report
A summary of monthly and year-to-date performance statistics are displayed in a concise, single-page PDF.
The Regression Chart
The Regression Chart shows the Actual efficiency for every entry in the selected date range (grey squares). It compares the Actual Efficiency Regression Line (best line of fit) to the average CPLV Efficiency Regression Line to indicate the direction of performance. If the Actual Efficiency Line is approaching the CPLV Efficiency Line, the performance is improving for that time period. If it is spreading from the CPLV Line, then performance is degrading.
The Diagnostics Frequency Chart
The Diagnostics Frequency Chart shows the occurrence of Diagnostics and Limit Alarms during the selected date range. It makes it simple to see what problems EffTrack identified, their frequency and whether they have been corrected.
The Monthly Management Report
The Monthly Management Report is a three-page PDF per chiller, emailed at the first of every month. It includes the Monthly Report, Regression Charts and Diagnostic Frequency Chart. See at a glance chiller performance and cost reporting, regression trending and what operational problems may have occurred.
Step 5 - Make Operational Improvements Based on the Reports
This example demonstrates the sequence of events for correcting a problem with multiple possible causes.
A chiller manufacturer technician on a routine service call changed the refrigerant level controller set point in the condenser to a factory default setting. This caused the liquid refrigerant level in the condenser to drop and lose the liquid seal, allowing hot gas to bypass with the liquid refrigerant into the evaporator. The result was an immediate slight increase in evaporator pressure, undetectable by the operator. However, EffTrack also detected the drop in compressor capacity and efficiency and immediately sent email notifications to facility personnel.
An evaluation of the refrigerant level controller revealed that it was not reading properly and was displaying an incorrect refrigerant level. The plant operators solved this problem by going through the steps in EffTrack troubleshooting, isolating the problem with the condenser refrigerant level. Adjustments were made on the liquid set point and the problem was eliminated, restoring the efficiency to normal.
Step 6 - Measure Improvements and Cost Savings
By responding to this problem, this customer was able to achieve a $60,000 a year cost avoidance. The problem was so concealed, it may never have come to light without the EffTrack program.
EffTrack makes it easy to calculate and prove the cost savings of operational improvements, which will increase management's awareness and appreciation of the operations and maintenance program.