EA-SAS Cooling

EA-SAS Cooling is a Digital Twin of the cooling/refrigeration system, designed to reduce electricity consumption through continuous system monitoring and automatic Set Points control

Digital Twin for various system configurations:

  • Different refrigerants: ammonia, CO2, HFCs (hydrofluorocarbons, e.g. freon);
  • Screw, reciprocating and other compressors;
  • Dry expansion and liquid overfeed systems;
  • Various types of condensers and evaporators;
  • Single compression and multi-compression cycles;
  • Different applications: freezing, chilling, cold storage, air conditioning, air drying and other. 

Problems to be solved:

  • How to reduce electricity consumption?
  • How to control Cooling/Refrigeration process according to variable product quantity and product type?
  • How to track the real efficiency indexes (EER, COP) online and know the real-time state of the system? 
  • How to determine actual minimal costs needed to ensure technological requirements and avoid surplus energy consumption? 

EA-SAS Cooling functionality:

  • Calculation and tracking of refrigeration energy consumption;
  • Predicting refrigeration demand;
  • Calculation and tracking of Compressors operation state and KPI’s: COP, isoentropic and volumetric efficiency and other;
  • Calculation and tracking of Condenser efficiency;
  • Calculation and tracking of Evaporators efficiency; 
  • Required evaporation temperature control Set Point recommendations;
  • Required condensing temperature control Set Point recommendation;
  • Equipment deterioration monitoring; 
  • Demand-response and price-based optimization. 

Benefits:

  • Constant refrigeration system maintenance is ensured without additional costs for qualified personnel;
  • Measures for reducing Refrigeration system energy consumption are determined;
  • Refrigeration system efficiency is automatically calculated and tracked;
  • User is informed about a tendentious drop of refrigeration system efficiency;
  • Presented information about equipment deterioration helps to prevent larger failures, plan maintenance repairs and costs.
  • Routine equipment maintenance (such as condenser cleaning, ice release from evaporators) is recommended based on actual need;
  • Actual cooling usage is tracked and compared with historical data, the user is notified about surplus cooling consumption;
  • Important information that helps to justify needed refrigeration system investments (an installment of variable frequency drives, new or more powerful condensers, and others) is collected. 

Case-study:

REFERENCE

AB Rokiškio sūris is one of the largest manufacturer of the dairy products in Lithuania. In order to produce a high quality product, an energy-intensive cooling and refrigeration process is necessary. In pursuit to reduce electrical energy consumption in refrigeration systems it was decided to implement Digital Twin. Cooling system is based on the two-stage refrigeration system, there are 4 compressors at first stage and 2 compressors at second stage.
Refrigeration system produces +2÷5°C chilled water and -30°C refrigerant. After EA-SAS Cooling was implemented, an actual refrigeration energy consumption was metered. Demand for refrigeration is forecasted based on production volume. At EA-SAS Cooling, Refrigeration mass and energy balance are calculated online, and efficiency indexes of both condenser and compressor are calculated online, as well as overall refrigeration system COP. Data from smart-metering and Scada is collected and analyzed in the real time at one EA-SAS platform. Set points for Refrigeration compressors operation are calculated at EA-SAS Cooling and sent to refrigeration control system automatically without human interaction. Project allowed to reduce the refrigeration system electricity consumption, it lets us to monitor the compressor room operation remotely and to know the system’s COP in real time, thus allowing to make maintenance decisions. Historical data is collected at database. Energy Advice specialists implemented and installed the system, trained the personnel and consults us regarding refrigeration system operation if needed. We recommend EA-SAS Cooling for the companies that seek for Refrigeration systems efficiency and electricity consumption reduction.


AB Rokiškio sūris
Artūras Vainiūnas, Technical director

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