Chiller Plant Management
Coordinated control of chillers, pumps and cooling towers with live alarms and trends
A chiller plant management system that controls chillers, pumps and cooling towers as one plant, with real-time alarms, trend analysis and predictive maintenance information for data centres and large buildings.
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What the system does
Cooling is one of the largest loads in a data centre or commercial building, and a chiller plant run as separate machines rarely runs efficiently. Each chiller, pump and cooling tower follows its own local controller with no view of the whole plant.
Our chiller plant management system brings the plant under one PLC-based control panel and SCADA. It sequences chillers, pumps and cooling towers to the cooling demand, raises alarms in real time and records trends that show how each machine is performing.
Operating hours, trips and performance trends feed predictive maintenance, so equipment is serviced on condition and its life is extended.
- 01
Plant sequencing
Starts, stops and stages chillers, primary and secondary pumps and cooling towers according to cooling demand.
- 02
Optimal control
Coordinates setpoints and equipment selection across the plant so machines run closer to their efficient operating range.
- 03
Real-time alarms
Immediate alarms on chiller trips, pump failures, flow and temperature deviations, with acknowledgement and history.
- 04
Trend analysis
Historian trends for supply and return temperatures, flows, run status and power, for performance review.
- 05
Predictive maintenance
Run hours, start counts and performance trends point to equipment that needs attention before it fails.
- 06
Integration with chiller controllers
Reads chiller controllers over Modbus or BACnet and connects to BMS, EMS and centralised monitoring.
Across the automation layers
What the solution does at each layer of your facility.
L1 · Field
Connects temperature sensors, flow meters, differential pressure sensors and pump and fan status points.
L2 · Control
Provides a PLC-based chiller plant control panel with VFD panels for pumps and cooling tower fans.
L3 · Supervision
Shows plant graphics, setpoints, alarms and trends on SCADA operator stations.
L4 · Enterprise
Feeds cooling energy data into energy and PUE reports and maintenance planning.
Scope and specification
| Item | Scope |
|---|---|
| Equipment controlled | Chillers, primary and secondary pumps, cooling towers |
| Control functions | Sequencing, staging, setpoint management, auto/manual operation |
| Monitored points | Supply and return water temperatures, flow, differential pressure, run and trip status |
| Drives | VFD panels for pumps and cooling tower fans |
| Alarms | Real-time alarms with acknowledgement and history |
| Analysis | Trend analysis and run-hour based maintenance information |
| Protocols | Modbus, BACnet |
| Panels | PLC-based chiller plant control panels manufactured in our own facilities |
What it means for operations
Sectors served
- Plant runs as one systemChillers, pumps and towers respond together to the cooling load instead of fighting each other.
- Earlier warning of problemsReal-time alarms and trends show deviations before they become cooling failures.
- Longer equipment lifeBalanced run hours and condition-based maintenance reduce wear on individual machines.
- Cooling energy you can measurePlant data feeds energy and PUE reporting, so the effect of changes is visible.
Frequently asked questions
Can you integrate chillers from different manufacturers?
Yes. We read chiller controllers over their communication interfaces, typically Modbus or BACnet, and control the plant from a common PLC panel. Each chiller’s own safety controls remain in place.
Do you supply the control panels?
Yes. Chiller plant control panels and VFD panels are designed and manufactured in our own facilities, then tested before dispatch.
Can the system be retrofitted to an operating plant?
Yes. Retrofits are staged so that chillers are switched to the new control one at a time while the plant keeps running.
Where have you delivered chiller plant management?
We have delivered chiller plant management for enterprise data centres and pharma facilities, often together with BMS and EPMS.
Let’s start by understanding your facility
Send us a short description of the site and its current systems, and an engineer will come back with clear next steps.