Industrial processing water system maintains industrial device required temperature or pressure by removing heat from industrial processing. It consists of cooling towers and cooling circulation pumps. It provides cooling water to industrial processing equipment to remove heat and cools the water to a lower temperature using cooling tower.

PSP-PCW is a universal plug-and-play (PNP) control system designed for industrial processing cooling plants. It supports up to ten (10) cooling water pumps (with or without VFDs), and ten (10) cooling towers (with or without VFDs).

The PSP-PCW system includes three levels of controllers: PSP, AIM, and Digi.

• PSP is the primary controller, managing the entire cooling water plant system from the main control station. It processes, stores, and presents data from the system’s subsystems (pumps and cooling towers). It also provides optimal control and coordination of these subsystems. The PSP communicates with a supervisory controller via an internal or stationary IP address.
• AIM controllers act as subsystem supervisory controllers:
  • AIM-CT: for cooling towers
  • AIM-CWP: for cooling water pumps

These virtual controllers are embedded within the main control station.

• Digi controllers are individual equipment controllers located within or near each piece of equipment:
  • Digi-CT: for cooling towers
  • Digi-CWP: for cooling water pumps

The main control station connects all Digi controllers through a multi-port gateway.

Customers can purchase PSP-PCW directly from Bes-Tech and hire local HVAC contractors for installation and setup. Bes-Tech engineers provide online support for installation and commissioning (CX) as needed.

Bes-tech provides customers turn-key projects as well. Call for details.

PSP-PCW shall result in substantial electricity cost savings, enhance system reliability and safety, and extended lifespans of pumps, fans, and valve actuators.

• Energy and/or Cost Savings: Reduction in electricity consumption or cost by 25% to 45%.
• Extended Equipment Lifespan: Increased equipment lifespan by over 5 years due to more efficient operation and reduced motor cycling or cold start/stop.
• Lower O&M Costs: Reduced operational and maintenance costs by 20% to 50%, primarily from fewer failures of compressors, pumps, and fans.
• Informative Preventive O&M: Automated FDD provides comprehensive equipment potential failure alarms to perform preventive O&M.
• Automated Equipment Failure Handling: PSP-PCW automatically makes up the failure equipment duties to prevent negative impact on chilled water production and allow O&M staff repair in calm and scheduled manner.
• Utility Incentives: Many utilities provide incentives to this technology and controllers. Consult your local utility energy program for details.

• PSP: Plug, Set, and Play: Easy installation with minimal setup required.
• Retrofit Existing Equipment: Can be installed with no impact on current system operation and no interference with existing equipment.
• New Plant Integration: PSP-PCW can be purchased and used as the Building Automation System (BAS) for new installations.
• Standalone or Integrated Operation: Includes a local workstation for system setup and graphical interface, with standard data communication ports for integration with any supervisory system or controller.

PSP-PCW leverages AI technologies, solid engineering fundamentals, proven industrial practices, and patented technologies to optimize the performance of process cooling water plant systems. Key principles and advantages include:

1. Optimal Cooling Water Temperature Setpoint: AI determines the optimal cooling water supply/return temperature setpoints based on real-time load, ambient conditions (dry bulb and wet bulb), and cooling tower fan speed.
2. Optimal Cooling Water Flow Setpoint: AI determines the optimal cooling water flow setpoint based on real-time load, supply water temperature, and return water temperature.
3. Minimum Discharge Pressure Setpoint: AI determines the plant optimal minimum discharge water pressure setpoint based on cooling water flow, supply and return water temperature, and Digi-ARV (negative air release valve).
4. Pump On/Off Control for Maximum Efficiency: AI uses a virtual pump flow meter to optimize pump on/off sequences based on real-time demand, ensuring the pump operates in its high-efficiency zone.
5. Pump Speed Control: Modulate pump speed to maintain both the minimum discharge pressure and water flow setpoints at or above the setpoint.
6. Cooling Tower On/Off Control: AI leverages N+1 principles, 80% rule, and minimum cooling tower water flow ratio to maximize the number of cooling towers in operation.
7. Cooling Tower Fan Speed Control: AI manages fan speed based on the swarm bee principle.
8.  Dual Safety Protection for Fans and Pumps: Motor doctor technology and virtual pressure sensors protect compressor motors from issues like overcurrent, phase dropouts, vibration, and pressure imbalances. They also protect indoor and condenser fan motors from overcurrent, phase issues, and vibration, eliminating conventional pressure sensor failure points and reducing maintenance costs.

1. What are some important benefits to Facility Owners that install PSP-PCW®?

The PSP-PCW® provides project payback in less than two years. In addition to energy savings, the PSP-PCW® reduces O&M costs significantly and improves system reliability and safety.

2. Why do Facility Service Providers/Companies recommend PSP-PCW® to their clients?

Facility Service Providers/Companies have an obligation to reduce energy consumption annually for their clients and installing PSP-PCW® will ensure satisfaction with this requirement. Moreover, installing the PSP-PCW® will significantly reduce O&M efforts and costs.

3. What important facts should ESCOs, and Energy Consultants know about the PSP-PCW®?

Industrial processing cooling plants are commonly used in industrial facilities. This is a significant market for performance contracting and energy retrofits using the PSP-PCW®.

4. Why should MEP and BAS Contractors install PSP-PCW®?

Offering PSP-PCW® to their clients can significantly increase revenue without head count increases. It will also increase the chances of renewing and/or adding new service contracts.

5. How is the PSP-PCW® integrated with BAS systems?

The PSP-PCW® is a PSP automation system. It can integrate with any BAS system through native Modbus and/or other protocols.

6. Can PSP-PCW® reuse the existing sensors and actuators?

Absolutely!

7. Does PSP-PCW® vary the cooling water flow?

The cooling water flow rate varies between 60% to 100% rated flow. The cooling water flow rate decreases as the cooling supply water decreases. The cooling water flow rate is determined based on the heat transfer principles.

Bes-Tech, Inc. Corporate Office:

6916 N 97th Circle
Bldg B, Suite J, Mailbox 13
Omaha, Nebraska 68122-3037
O: 402-502-2340 I F: 402-502-2283
www.Bes-Tech.net