Case study: The facility was experiencing issues with its cooling system, specifically related to the operation of the fan units in the dry coolers during the winter season. Symptoms: Intermittent operation of the dry cooler fans resulting in unstable temperature and inefficient operation of the cooling system. Problem: The temperature of the dry cooler was controlled by pulse width modulation (PWM), which resulted in incorrect fan operation. There was also a lack of synchronisation between the two independent dry coolers, resulting in uneven cooling and temperature fluctuations. Solution: A multi-layered approach was implemented to solve the problem. After a thorough pattern, operational analysis and AI-based anomaly detection using the HiPerWare platform, the controller settings were adjusted: the variable frequency drive (VFD) controllers were recalibrated. The aim of this adjustment was to improve the responsiveness and stability of the system when controlling the fan speeds. Furthermore, synchronising the two independent dry coolers ensured that both units worked together/in balance, preventing one unit overworking while the other was idle. Results: The implementation of these solutions led to significant improvements. The fans began to run continuously without unexpected shutdowns, resulting in more consistent cooling performance. With smoother operation and reduced fan cycling, equipment wear and tear was reduced, extending the life of cooling system components and reducing maintenance costs. The facility benefited from cost savings and increased operational reliability, as well as improved performance.
