SMART CONTROLS
Jason Hibbs of Jet Environmental Systems discusses HVAC controls development and integration in warehouse applications.
ndustrial applications are complex. A band is set – packaged generic pharmaceuticals for example have a control band between 15 and 25 degrees Celsius so heating and cooling demand is determined as temperatures encroach on the lower and upper limits. The tighter the band of acceptable warehouse temperature, more energy is required as the heating and/or cooling demand is higher or more frequent and consequently more expensive to run. There are techniques deployed to reduce energy consumption – controls that adopt free cooling routines into their programming to make use of the cool night-time air in summer to delay the call for mechanical cooling during the day were considered avant-garde not long ago. From a practitioner’s perspective there seem to be three
concurrent streams of development for warehouse HVAC system controls: ■Criticality of performance and 24/7 monitoring ■Energy consumption ■Integration with building management systems (BMS).
HVAC systems cover a myriad of applications across a Energy
consumption data from an HVAC system can provide a great insight into how a building performs, how
operational processes as simple as door
management can have a huge eff ect on running costs.
broad range of sectors – however the solutions tend to fi t in one of the three categories described below. It’s probably worthwhile reviewing these solutions to understand what the controls set out to achieve. In its simplest form, a warehouse HVAC system provides
frost protection for sprinkler systems – with the drive for zero local carbon emissions this has led to the adoption of heat pumps to provide heat. It is worth noting that cold starting a heat pump in a situation that is least favourable for heat pumps can be problematic and so system design requires careful thought.
Second in terms of design complexity and infrastructure demand is heating and ventilation where energy is consumed to provide heat. When not providing heat, the system circulates air to provide ventilation and evaporative cooling through air movement during the summer. Full temperature control is the most comprehensive HVAC application that itself ranges from broad temperature band solutions like pharmaceuticals to close tolerance control of precise manufacturing environments or temperature and humidity control for fi ne wines or confectionary, for example. It should be no surprise that as the demands of the system
increase, so does the energy required to achieve the result and the criticality of the controls managing the HVAC solution.
Performance and monitoring The role of the HVAC system is becoming more prominent
32 July 2024 •
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Industrial smarts I
and often a critical component in the management of goods passing through a warehouse. Product quality, effi cacy and shelf-life can all be aff ected by temperature control. Consequentially the demand for instant information and KPI reporting has meant that the control system no longer operates in isolation. System controls are now accessible by PC and phone apps, providing instant information and alarm messages out to a hierarchy of responders. Increased numbers and type of monitoring sensors available; typically, temperature, humidity, CO2
, CO in an
HVAC system and the communication capability to share that data has facilitated the remote measurement and management of systems and compliments the suite of BMS dashboards used for broader building management. The increased number of sensors on HVAC plant itself
allows for increased effi ciency by having inverter-controlled compressors, variable fan speeds, refrigerant fl ow control, timed and zone control providing optimum energy usage. In addition to real-time alerts and system operation, information is being collated to perform dynamic servicing schedules and effi cient engineer planning. Increased visibility and the ability to control remotely has made huge effi ciencies in service operations. It’s no longer necessary for an engineer to attend site to diagnose an issue and then order parts and return. Diagnosis, restarts, adjustments, isolation of circuits and ordering of spare parts can be done as an issue is raised, dramatically improving response times at minimal cost and reducing travelling miles. The diagnosis also improves spares ordering accuracy, better inventory control, and lower logistics costs. The service function has improved in every aspect as a direct result of better controls and communication.
Energy consumption
The cost of heating and cooling has always been a consideration but as energy prices increase and more expensive electricity has usurped gas as the preferred fuel, consumption data is vital in facilitating management decisions. Energy consumption data from an HVAC system can provide a great insight into how a building performs, how operational processes as simple as door management can have a huge eff ect on running costs. Data collation and mapping against operational cycles
provides an insight into how operations eff ect the demand for heating or cooling; Heat gains from MHE, processes, goods in and out, lighting, co-packing all create a consequential demand for energy. At the building level, energy maps can illustrate how
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