Chillers anomaly

Another case study about anomaly detected was in the chilling warehouse. The customer saved 12% of energy consumption and avoided very expensive unplanned repairs.

In large cold storage warehouse, the temperature should have been maintained at -18 degrees Celsius. According to our customer, everything appeared to be fine, but one of the chillers required more frequent repairs compared to the others. Energy consumption showed numerous peaks and was significantly higher than similar equipment in another building. The customer was unable to determine the exact issue with the chiller and called the HiPer it! team to analyze the performance of all three chillers. After analysing the operational data using the HiPerWare platform, it was discovered that the first and second chillers were functioning correctly, while the third chiller showed abnormal behavior due to a programming automation error.

Identifying this anomaly would have been nearly impossible without continuously collecting operational data from the equipment with the high frequency, literally every second. As a result, the customer resolved the issue with the chiller, confirmed the correct settings, and continued to analyse its performance using the HiPerWare platform. Consequently, the company achieved a 12% reduction in energy consumption and avoided costly unplanned repairs to the chillers

Case Study: Chiller Checkup

During a checkup, the HiPerWare platform identified a problem with one of the chillers and refrigeration automation systems in a cold warehouse facility. After correcting the problem, the customer saved 12% energy and the cost of unplanned equipment repairs.


Excessive energy consumption of chillers to maintain a temperature of -18C. The current SCADA system could not determine the cause.


Instrumental analysis, measurement of chiller operating patterns – energy consumption, temperature, pressure 1 measurement per second showed that chiller #3 was operating in an incorrect mode, turning on and off several times per minute. This resulted in increased wear and energy consumption.


Reconfiguring the automation and continuing to track equipment operation with HiPerWare solved the problem. Without HiPerWare, it would’ve been difficult to perform such in-depth diagnostics without shutting down the equipment. The implementation was non-intrusive, without shutting down the equipment, and the data was collected frequently, like a cardiogram, allowing for an accurate understanding of the ongoing operational processes.


After correcting the problem, the customer saved 12% energy and avoided the cost of unplanned repairs to expensive equipment.

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