Air-cooled chiller demand flow control algorithm

Air-Cooled Chiller Demand Flow Control Algorithm – EKG M&E Sdn Bhd

At EKG M&E Sdn Bhd, we implement advanced demand flow control algorithms for air-cooled chiller systems, enabling dynamic optimization of cooling performance based on real-time building or process load requirements. These algorithms intelligently manage chilled water and refrigerant flow to improve energy efficiency, reduce operational costs, and enhance system responsiveness—especially in multi-zone or variable load environments.

What Is a Demand Flow Control Algorithm?

A demand flow control algorithm is a smart control strategy that adjusts the operation of chillers, pumps, fans, and valves based on actual system demand. It continuously analyzes sensor data (temperature, pressure, flow rate) and modulates system components to maintain optimal conditions with the lowest energy input.

Key Features of Our Demand Flow Control Algorithm

• Variable Flow Regulation
  Modulates chilled water and refrigerant flow using VSDs (Variable Speed Drives) on pumps and fans.

• Dynamic Setpoint Adjustment
  Continuously adjusts evaporator leaving water temperature, compressor staging, and expansion valve behavior based on real-time load.

• Compressor Load Balancing
  Distributes run time across multiple compressors to prevent overuse and reduce wear.

• Sensor Integration & Feedback Loops
  Collects real-time data from:

  • Flow meters

  • Pressure and temperature sensors

  • Return and supply water loops

  • Zone-level thermostats or process demands

• Energy Optimization Logic
  Minimizes total system kW/ton by automatically selecting the most efficient operating point for each component.

• Fault Tolerance & Safety Monitoring
  Includes alerts and fallback conditions in case of pressure, temperature, or flow anomalies.

Benefits of Using a Demand Flow Algorithm

• Saves 10–40% in energy consumption, especially at part load

• Reduces short cycling and compressor wear

• Increases cooling system responsiveness and stability

• Supports load prioritization for critical zones or equipment

• Enables better integration with BMS and smart HVAC controls

• Contributes to LEED certification and green building goals

Ideal Applications

• Commercial buildings with variable occupancy

• Data centers and temperature-sensitive environments

• Hospitals, malls, manufacturing facilities

• Chillers operating in multi-zone systems or VAV configurations

• Systems undergoing retrofits or energy efficiency upgrades

Why Choose EKG M&E Sdn Bhd?

• Proven expertise in HVAC controls and algorithm deployment

• Experienced with all major air-cooled chiller brands and control platforms

• Ability to customize algorithms for unique site conditions

• End-to-end support from sensor setup to performance tuning

• Post-deployment reporting with measurable energy savings data

Final Thoughts

Modern chiller systems demand smart controls to meet today’s energy and performance standards. With EKG M&E Sdn Bhd’s air-cooled chiller demand flow control algorithm, you can achieve precision cooling, optimal energy use, and long-term system reliability.
Contact us today to learn how we can upgrade your chiller system with intelligent flow control.