Illustrative scenario
Chiller circuit leak isolated without a shutdown
Illustrative scenario — representative of common industrial IoT applications
WaterManufacturing — automotive, plastics & rubber
A leaking cooling loop found and isolated with the line still running.
An automotive plant
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
A closed cooling loop was making up far more water than a closed loop should. Nobody knew which of several circuits was responsible.
02
Cost
1 loop isolated — Identified by sub-meter divergence, with no production stoppage.
03
Fix
Sub-meters on each cooling circuit's make-up line · Continuous differential comparison between circuits · Threshold alerting on make-up rate
04
Restored
One circuit named, isolated and repaired on a planned outage
In full.
Illustrative scenario — representative of common industrial IoT applications.
The problem
A closed cooling loop was making up far more water than a closed loop should. Nobody knew which of several circuits was responsible.
What would be installed
- Sub-meters on each cooling circuit’s make-up line
- Continuous differential comparison between circuits
- Threshold alerting on make-up rate
What changes
Before — One aggregate make-up figure, four candidate circuits After — One circuit named, isolated and repaired on a planned outage
The number
1 loop isolated — Identified by sub-meter divergence, with no production stoppage. Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
In one line
Sub-metering does not find leaks. It narrows them until the answer is obvious.
What the data looked like.
Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.
| Interval | Loop A (L/h) | Loop B (L/h) | Loop C (L/h) |
|---|---|---|---|
| D1 0:00 | 21 | 21 | 23 |
| D1 4:00 | 21 | 19 | 26 |
| D1 8:00 | 24 | 19 | 27 |
| D1 12:00 | 20 | 19 | 32 |
| D1 16:00 | 24 | 21 | 36 |
| D1 20:00 | 22 | 17 | 36 |
| D2 0:00 | 22 | 21 | 39 |
| D2 4:00 | 21 | 18 | 40 |
| D2 8:00 | 25 | 21 | 45 |
| D2 12:00 | 20 | 20 | 45 |
| D2 16:00 | 20 | 20 | 53 |
| D2 20:00 | 25 | 20 | 52 |
| D3 0:00 | 22 | 18 | 55 |
| D3 4:00 | 22 | 21 | 57 |
| D3 8:00 | 24 | 18 | 60 |
| D3 12:00 | 20 | 17 | 61 |
| D3 16:00 | 20 | 18 | 67 |
| D3 20:00 | 24 | 20 | 69 |
| D4 0:00 | 24 | 17 | 72 |
| D4 4:00 | 23 | 20 | 74 |
| D4 8:00 | 23 | 17 | 78 |
| D4 12:00 | 21 | 20 | 78 |
| D4 16:00 | 24 | 19 | 82 |
| D4 20:00 | 23 | 20 | 81 |
| D5 0:00 | 20 | 17 | 88 |
| D5 4:00 | 22 | 18 | 87 |
| D5 8:00 | 20 | 19 | 90 |
| D5 12:00 | 21 | 19 | 94 |
| D5 16:00 | 20 | 19 | 95 |
| D5 20:00 | 23 | 18 | 100 |
| D6 0:00 | 24 | 20 | 102 |
| D6 4:00 | 20 | 20 | 103 |
| D6 8:00 | 20 | 19 | 105 |
| D6 12:00 | 22 | 17 | 111 |
| D6 16:00 | 20 | 19 | 113 |
| D6 20:00 | 22 | 20 | 115 |
| D7 0:00 | 20 | 19 | 119 |
| D7 4:00 | 23 | 20 | 122 |
| D7 8:00 | 23 | 20 | 122 |
| D7 12:00 | 22 | 19 | 125 |
| D7 16:00 | 21 | 20 | 129 |
| D7 20:00 | 21 | 17 | 129 |
| Before | One aggregate make-up figure, four candidate circuits |
|---|---|
| After | One circuit named, isolated and repaired on a planned outage |
Illustrative dataset — a representative operational profile, seeded and deterministic, not measured at any site.
What changed.
Before
One aggregate make-up figure, four candidate circuits
After
One circuit named, isolated and repaired on a planned outage
1 loop
isolated
Identified by sub-meter divergence, with no production stoppage.
Source: Illustrative scenario, not a client result. Figure is representative, not measured. [TOM-REVIEW]
Where to go next.
The sector, the sibling studies, and the calculator that runs this same arithmetic on your own numbers.
Cooling towersWaterManufacturing — automotive, plastics & rubberBuilding Materials & Heavy Industry
Cooling tower blowdown optimization
A plastics manufacturing plant
Blowdown running on a timer instead of on conductivity, discharging good water.
1 setpointchanged
Illustrative scenario
WaterFood & Beverage Processing
Weekend ghost flow in an empty building
A food processing plant
Water still running through an empty plant all weekend — around a fifth of the monthly bill.
~20%of the monthly water bill
Illustrative scenario
Predictive maintenanceWaterBreweries & Beverage
A failing diaphragm pump, caught before it failed
Carlsberg Canada
A failing diaphragm pump caught before it failed — 540,000 L/day of loss prevented.
540,000 Lper day
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