Effective Antifreeze Monitoring With The Cool Gauge RT-100
Industrial chillers play a crucial role in various industries, including manufacturing, food processing, pharmaceuticals, and HVAC systems. These cooling systems are designed to maintain specific temperatures essential for production processes, equipment efficiency, and product quality. However, industrial chillers are susceptible to freezing, corrosion, and bacterial growth, all of which can compromise their performance and longevity. One of the most effective ways to protect industrial chillers is by using glycol antifreeze. This specialized coolant helps maintain optimal system function, prevents costly downtime, and extends equipment lifespan.
The primary reason for using glycol antifreeze in industrial chillers is to prevent freezing. When temperatures drop below freezing, water-based cooling systems are at risk of ice formation. Ice expansion can lead to pipe bursts, blockages, and severe damage to the chiller’s components. Glycol lowers the freezing point of the fluid, ensuring that the coolant remains in a liquid state even in extremely low temperatures. This is especially important in facilities where chillers are exposed to outdoor conditions or operate in cold climates.
Monitoring antifreeze levels in industrial chillers is crucial for maintaining efficiency, preventing damage, and ensuring system longevity. Antifreeze, typically a glycol-based solution, prevents freezing in low-temperature environments and enhances heat transfer within the chiller system. If antifreeze concentration falls outside the optimal range, it can lead to several operational issues such as severe damage to pipes, heat exchangers, and other critical components. Ice formation leads to blockages, increased pressure, and potential system failure. On the other hand, excessive antifreeze concentration reduces heat transfer efficiency, forcing the system to work harder and increasing energy consumption.
Corrosion prevention is another critical factor. Industrial chillers often have metal components that are susceptible to rust and scaling. Proper antifreeze levels contain inhibitors that protect against corrosion, extending the lifespan of the equipment and reducing maintenance costs.
Additionally, microbial growth and contamination can occur if antifreeze is not monitored. Over time, degradation of the fluid can lead to sludge buildup, reducing efficiency and potentially causing clogging.
Regular monitoring ensures that the chiller operates at peak performance, preventing costly repairs and downtime. Routine testing of pH, glycol concentration, and inhibitor levels helps maintain a balanced and efficient system.
The Cool Gauge RT-100 is an advanced, reliable solution for monitoring antifreeze levels in process chilled water systems. It offers continuous, accurate measurements of common heat transfer fluids (HTFs) such as Mono-Ethylene Glycol (MEG), Mono-Propylene Glycol (MPG), ALV, and ALV+, along with system temperature readings.
Equipped with 4-20mA and RS485 Modbus capabilities, the RT-100 enables seamless integration with existing Building Management Systems (BMS) or standalone panels, allowing real-time data access. Its advanced microprocessor features an OLED display and an integrated datalogger capable of storing up to 56 days or 80,000 data points of operational temperature and concentration values.
By maintaining optimal HTF concentrations, the RT-100 helps preserve efficient fluid viscosity, leading to reduced energy consumption and operational costs. It also minimizes manual sampling errors and prevents potential glycol overdosing, which can increase fluid viscosity and pumping costs. Furthermore, the RT-100 provides early warnings of potential issues, such as low glycol levels, through alerts via email or SMS, enhancing system protection and reducing the risk of freeze damage.
Incorporating the Cool Gauge RT-100 into antifreeze monitoring protocols ensures precise control over cooling systems, promoting efficiency, cost savings, and system longevity.
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A clearly identified need for greater control and management of the site’s ‘production critical’ adiabatic cooling system. One of the key parameters to be kept under strict control is the HTF level, as, by monitoring and controlling the optimum HTF (inhibited) reserve, the system receives the necessary protection from freezing, corrosion and scale. Continuous collection of vital HTF data by Cool Gauge is delivered to the controller via Cool Gauge’s RS485 capability which effectively enables accurate dosage of the selected HTF to the system.
The HTF reserve is maintained accurately by adjustable high and low set-points in the controller. This data can also be seen by remote viewers in real-time, and, if necessary, alerts sent to operators via text or email if the set-points are breached. This facility warns operators of any impending problems such as drops in the HTF level due to leaks.
This graph shows data as viewed by operators after logging in to the cloud account. It can be seen that steady HTF conditions are maintained over the 13 month time-scale selected. Fluctuations, such as those seen if a manual shot dose of HTF is made, can be easily noted as a rise in the monitored level. The on-going HTF system average is shown in the grey box. Any historical data can also be seen by adjusting the start and finish dates in the cloud website.
“Exciting news! Cool-Gauge is featured in the latest edition of ACR News! We are thrilled to announce that our innovative product, the Cool-Gauge RT-100 cooling system monitoring device, was recently highlighted in an article published by ACR News. This article shines a spotlight on the advanced technology and unique features of our RT-100, which offers unparalleled monitoring capabilities for cooling systems, helping to improve efficiency and reliability. We’re proud to be commited to innovation and customer satisfaction in the HVAC industry!”
