CASE43 · Manufacturing · Integrated utility balance
Tracing chiller staging, AHU resistance and compressor losses on one time axis
Chillers, air handling and compressed air are diagnosed as an integrated utility portfolio. Service-specific KPIs and short-interval events reveal operating questions that monthly consumption cannot explain.
01 · CASE ANALYSIS
Integrated rather than isolated diagnosis
For chillers, assess load, power, UPI/COP and water conditions. For AHUs, assess filter differential pressure, outdoor-air dampers and return-air conditions. For compressors, assess flow, pressure, units and loading/unloading.
The objective is to identify whether each utility is matched to actual demand while maintaining production service.
02 · CASE ANALYSIS
Chiller and air-handling observations
Chiller average UPI was 0.84 kWh/RT, COP 4.20 and load ratio 55%. Actual average operating count was 2.1 units versus a load-derived requirement of 1.2.
The 0.9-unit margin is a diagnostic signal requiring reserve, minimum-load and hydraulic review. It is not an immediate instruction to stop one unit. Some AHU filter pressure drops were approximately 19–22 mmAQ versus 12–13 mmAQ elsewhere.
| Utility | Indicator | Observation |
|---|---|---|
| Chillers | Actual / required average units | 2.1 / 1.2 |
| Chillers | UPI / COP / load ratio | 0.84 kWh/RT / 4.20 / 55% |
| AHUs | Filter differential pressure | 19–22 versus 12–13 mmAQ |
| Compressed air | UPI / load ratio | 0.126 kWh/m³ / 81% |
| Compressed air | Mean / maximum instantaneous loss | 3.1% / 31.7% |
03 · CASE ANALYSIS
Compressed-air events
Monthly average compressed-air UPI was 0.126 kWh/m³ and average system load ratio 81%. Average system loss was approximately 3.1%, while a one-minute maximum reached 31.7%.
Investigate the demand, pressure, active-unit and unloading state at the event. Neither a differential-pressure spread nor an instantaneous maximum is an annual saving rate.
04 · CASE ANALYSIS
Proposed utility portfolio
The source annual utility baseline was 10,403,571 kWh, with 444,832 kWh/year potential, approximately 4.3%, and KRW 49,821,132/year expected benefit.
Cooling accounted for the largest potential. Rounded item values sum to 1 kWh more than the reported aggregate, which is preserved as supplied.
| Utility | Baseline kWh/year | Potential kWh/year | Potential rate |
|---|---|---|---|
| AHUs | 1,284,297 | 12,843 | 1.0% |
| Cooling system | 4,575,524 | 320,287 | 7.0% |
| Compressed air | 3,313,220 | 99,397 | 3.0% |
| Other utilities | 1,230,530 | 12,305 | 1.0% |
| Total | 10,403,571 | 444,832 | Approximately 4.3% |
05 · CASE ANALYSIS
Verification and application
Confirm sensor quality and comparable filter grades/airflows before attributing resistance differences to deterioration. Define whether pumps, towers and dryers belong inside each energy boundary.
Verify implemented changes with adjusted cooling load, production, weather, compressed-air demand and operating hours.
Source-value comparisons
Source figures · English edition
Figures correspond to those published in the Korean case. English titles, axes and legends are provided; published values and evidence boundaries are retained. Open a figure at full size to inspect small labels.
Source average running count 2.1 versus analytical requirement 1.2. The count gap is diagnostic evidence, not an energy-saving percentage.
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