Cooling Controls

Delta T Systems Creates a Custom Ambient Dew Point Solution

By Troy Dreier, Senior Editor, Compressed Air & Cooling Best Practices Magazine

A building materials manufacturer solved persistent dust buildup by using a custom chiller designed to operate below the ambient dew point, intentionally creating condensation on process equipment. This case study shows how Delta T Systems integrated ambient dew point sensors and variable speed drive (VSD) technology to optimize chilled water temperature, reduce cleanup time, and improve energy efficiency. The solution delivered measurable maintenance savings and became a scalable model for process cooling and chiller optimization across multiple facilities.

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Practical Free Cooling System Operation Techniques

By Clayton Penhallegon, Jr., P.E., Managing Member, Integrated Services Group

Free cooling offers a highly efficient alternative to chiller-based cooling, but its success depends on effective operation and control—especially during system transitions. This article outlines practical techniques for improving the shift between chiller and free cooling modes, minimizing temperature spikes and maintaining process stability in industrial environments. It also covers strategies for enhancing chiller performance under low-temperature conditions, optimizing heat exchanger startup, setting reliable control triggers and addressing maintenance and freeze protection. With proper tuning and operation, facilities can significantly increase free cooling hours, reduce energy use and extend chiller life without risking production disruptions.
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Why Pump System Assessments Matter

By Matthew Derner, Senior Manager, Education, Hydraulic Institute

Pump systems account for a significant share of energy use in industrial, commercial and municipal facilities, yet many operate far from optimal performance. This article explains how pump system assessments identify hidden inefficiencies in pumps, controls, piping and operating strategies, often uncovering opportunities to reduce energy consumption by 20–50% while improving reliability. Through real-world examples and best practices, it shows why data-driven pump system optimization is essential for lowering total cost of ownership and achieving long-term sustainability goals.
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Combined Design Does the Work of Two Cooling Systems at Bottling Plant

By Clayton Penhallegon, Jr., P.E., Managing Member, Integrated Services Group

Faced with the requirement for improved cooling, a blow molding plant chose to invest in a significant redesign of its cooling systems that combined two separate systems into a single, integrated system. The combined design leveraged the components to provide a more controlled, efficient system while also requiring less space than the alternative would have needed. 
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Cooling System Pressure Control for Efficiency and Process Stability

By Clayton Penhallegon, Jr., P.E., President, Integrated Services Group

Controlling cooling water flow is a critical element of high-performance cooling systems. Fortunately, pressure is a straightforward measurement that can be used as a cost-effective control input for flow control systems. Proper interpretation of pressure readings is required for accurate control at desired rates. This article covers pressure reading methods, control strategies and practical tips.
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Heat Exchanger Problem Causes and Troubleshooting

By Clayton Penhallegon, Jr., P.E., Integrated Services Group

Machine cooling high temperature problems are unfortunately all-too common in industrial plants. While the initial suspect is always the heat exchanger, there are several other factors that can be the underlying cause. Important steps can be taken to minimize the potential for heat exchanger fouling, but when problems do occur, careful examination of the machine and the system can help identify the problem efficiently and with minimal wasted effort.
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Challenges and Benefits of Digital Optimization for Chiller Plants

By Terri Perrin and Kiran Waghmare Mech. Eng., MEng, Global Product Manager, Johnson Controls

Using a combination of predictive analysis and historical information helps companies make sound decisions relating to CUP operations. Ever-changing loads, weather and utility prices combine with hundreds of components that all impact energy efficiency. While previous strategies focused on individualized equipment efficiency and automation, CUP optimization considers the complete system. 
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Holistic Controls for Superior Cooling Systems Efficiency, Part 2

By Clayton Penhallegon, Jr., P.E., Integrated Services Group

This article explores the distinction between standard system controls and holistic controls for highly efficient process cooling systems. Examples of high performance controls features and implementations are provided, and screening questions are listed for initial investigation of existing system and potential new systems.
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Holistic Controls for Superior Cooling System Efficiency, Part 1

By Clayton Penhallegon, Jr., P.E., Integrated Services Group

Process cooling systems are mandatory components of the production infrastructure in many plants. System efficiency is second only to operational performance (i.e. meeting the process requirements) in the design and operation of these systems, and many companies go to great lengths to attain system efficiency.  Many times, unfortunately, the actual system performance is well below the hoped for efficiency target.
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Vital Signs: Critical Instrumentation for Cooling System Health

By Clayton Penhallegon, Jr., P.E., Integrated Services Group

This article will discuss the instrumentation typically found in cooling systems and other plant utility systems, what other instruments and gauges should be used, how the instrumentation should be used, and good maintenance practices for instrumentation.
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The Need for KPIs and Production Data in Actionable Energy Monitoring Systems

By Staffan Akerstrom, P.E., CEM, and Paul Tate, P.E., LEED AP BD+C, Enpowered Solutions, LLC.

Have you ever woken in the middle of the night in a cold sweat wondering if your plant is using more energy than it should, putting you at a disadvantage as compared to your competition? Even if your energy monitoring or energy management system is in place you may not have the required insight to improve your performance and keep you competitive.
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Hershey Medical Center Saves $300,000 per Year in Energy Costs

By Mike Grennier, Contributing Editor, Chiller and Cooling Best Practices Magazine

Penn State Health Milton S. Hershey Medical Center, Hershey Pa., is all about energy and resource efficiencies, which is why it adopted a new approach to managing its chilled water operation. The approach, which revolves around a software and analytics platform used to optimize three chiller plants in addition to various equipment upgrades, has allowed it to save 4.16 GWh/yr in electrical energy consumption – and shave $300,000 off of its annual electrical costs. With an incentive from the local utility of $415,799, the multi-phased initiative achieved a payback of 4.3 years. 
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Healthcare HVAC ECMs Focus on Demand Control Ventilation

By Aircuity

HVAC systems can consume thirty percent (30%) of the total building energy needed in library, student union and classroom facilities.  In laboratory and research facilities, the HVAC energy consumption can be up to sixty percent (60%). When one considers the data of traditional airside Energy Conservation Measures (ECMs), simple paybacks range from low-cost, quick paybacks to capital-intensive long paybacks. The ECMs range from simple strategies, such as night setback and/or supply air reset, to full air handler replacement or variable air volume from constant volume conversion. However, few ECMs deliver more than thirty-five percent (35%) savings for the entire university campus.
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VSD Chillers Deliver Energy Savings Under Real World Operation

By Fred Berry, Johnson Controls

Manufacturers are under continual pressure to control costs without affecting operations or worker comfort and safety. Because energy ranks as one of the largest operating expenses, improving energy efficiency of mechanical cooling systems is one of the best ways to reduce operating costs. In a typical water-cooled chiller plant, the chiller itself accounts for most of the energy consumption. That’s why improving chiller efficiency is critical to controlling operating costs.
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Industrial Hydronic System Manual-Balancing Methods

By Brandon Aitken, ME, P.E., Engineering & Fabrication Manager, Blackhawk Equipment Corporation

Hydronic balancing in industrial heating and cooling systems is an often overlooked final step in startup and commissioning of new and modified hydronic systems.  Insisting on a complete system balance upon startup of a new or modified system is an inexpensive insurance policy for any design engineer or installation contractor to protect their reputation against a system that is not performing to design conditions.  There are several methods of hydronic system balancing utilized in commercial and hospitality buildings, however, they are rarely found in the manufacturing and industrial environments.
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Chrysler Reduces Annual Cooling Costs by 28% and Earns $200,000 DTE Energy Rebate

By Mike Flaherty, General Manager, tekWorx, LLC

Chrysler’s Technology Center (CTC), located in Auburn Hills, MI, is home to some fourteen thousand employees responsible for keeping the automotive giant in motion. Completed in 1991, the complex is essentially a small city, encompassing 5.3 million square feet situated on over 500 acres. In addition to corporate offices, the facility houses a full laboratory level of various wind tunnels with thermal testing capabilities, a 1.8-mile evaluation road, a noise/vibration facility, an electromagnetic compatibility center, an environmental test center (able to create rain, snow and extreme temperatures), and a pilot production plant.
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Central Plant Optimization Yields Up to 25% Efficiency Improvement for Pepco Energy Services’ Chiller Plant

By Tus Sasser, The Tustin Group

Pepco Energy Services’ (PES) Midtown Thermal Control Center (MTCC) in Atlantic City, New Jersey, sells chilled water and steam to multiple Atlantic City casinos, Boardwalk Hall and Pier Shops. PES is also responsible for stand-alone remote heating and cooling plants for the Atlantic City’s major casino’s as well as the Atlantic City Convention Center including its 2.4 Mw solar array.
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