Challenge
In the Netherlands, a prominent manufacturer relies on two cooling plants to provide process cooling across its production halls. These plants are managed by Trane Chiller Plant Manager, which oversees the controls operation of the cooling towers and chillers including a Trane Sintesis Advantage CGAF air-cooled chiller and Trane RTWD water-cooled chillers.
However, due to the rapid advancements in control technology, the control units installed with the cooling equipment have become outdated. Several crucial modules, including the main control module, are no longer available. Recognizing the need for an upgrade, The local Trane team recommended a controls enhancement as part of Trane Building Advantage improvement opportunities.
The manufacturer allocated a budget from their multi-year maintenance funds to address the Trane controls and other related improvements.
The main contractor for this project was SPIE, a reputable multi-technical service provider with 48,000 employees across forty countries. SPIE commissioned Trane to renew the process cooling control units.
A manager from SPIE Netherlands overseeing the procurement and organization of the control technology upgrade, emphasized: "Control technology typically has a shorter lifespan compared to the equipment it operates. New controls ensure that the existing cooling units perform better than before, and with reduced power consumption. This is another positive impact of an upgrade!"
Solution
In late 2023, Trane optimized the controls installation through a cost-effective upgrade, minimizing material waste by retaining components that still met the necessary standards.
The control cabinets for the Chiller Plant Managers, cooling towers, and chillers underwent a comprehensive upgrade with the replacement of outdated sections. While the customer had opted for the complete replacement of one control box that had been exposed to the elements for an extended period, it was determined that some internal components were still in good condition. Trane skillfully integrated various elements from the old cabinet into the new one.
Both cooling plants underwent significant enhancements, including the installation of:
• A new Trane Tracer SC+ main control system
• New Trane Tracer UC600 programmable controllers offering enhanced options and reliability
• New Pt1000 sensors for improved stability compared to the previous NTC sensors and
• A new touchscreen display to facilitate intuitive monitoring and control.
The optimization process was completed within five working days for each cooling plant. The controls upgrade required, among other things, the removal of circuits from control cabinets and the installation of emergency facilities. Although data traffic between the cooling system and the building management system was limited during the conversion, manual control ensured that the cooling operations continued smoothly, allowing uninterrupted production.
A SPIE representative expressed satisfaction with the seamless process: “Trane efficiently replaced the controls technology without disrupting ongoing production. Through proactive planning and open communication with the manufacturer's project leaders, any potential impact on production was carefully considered and mitigated. The cooling sytems kept functionning smoothly”
Results
The results of the controls upgrade have been exceptional, restoring the process cooling system in the production halls to perfect functioning condition. The implementation of Trane's new control technology has not only improved the reliability and energy efficiency of the cooling process but has also future-proofed the system. With advancements in software development, the new control units can easily stay up to date through software updates, ensuring optimal performance over time.
The SPIE representative highlighted the notable benefits of the new Trane controls, stating, "With the implementation of the new Trane controls at the cooling plant locations, it has become much easier and more intuitive to monitor and understand the entire system's operation. The high-level touchscreen interface provides a clear graphical representation of the entire operation with vital information, such as real-time data on cooling machines, temperature readings, active pumps, production demands, and the overall cooling provided. This enhanced visibility and comprehensive overview represent a significant improvement, empowering the customer to make informed decisions and optimize the cooling process effectively."
The seamless integration of Trane's control technology with the Honeywell building management system, using BACnet protocol, continues to streamline operations at the manufacturer's facility. The BMS can seamlessly interact with the cooling units by communicating with the Trane Tracer SC+ main control modules. Following the controls upgrade, Honeywell reconfigured the BACnet data points by referring to the detailed data point list provided by a Trane engineer.
The upgraded control technology opens up additional possibilities for the manufacturer. Although not implemented in this case, the new control technology enables the utilization of Trane Connected Services. With Trane Connected Services, Trane experts can remotely access and monitor the cooling plant through a secure VPN connection, providing valuable insights and assistance when needed.
The successful control technology upgrade has truly transformed the customer’s cooling system, enhancing its performance, efficiency, and connectivity, thus ensuring a smooth and optimized process for the manufacturer moving forward.
Learn more about Tracer SC+/Synchrony
Learn more about the Programmable Controllers
