Grasim Industries Limited | Water to Air Heat Exchanger | Water chiller Panel Cooling

Client: Grasim Industries Limited
Application: 220 kW Water-Cooled Chiller Drive Panel
Location: Industrial plant

Background

Grasim Industries Limited was operating a 220 kW water-cooled chiller for their process. The drive panel (VFS panel) of this chiller was continuously exposed to high ambient conditions inside the electrical room. Due to this, the panel was overheating and tripping frequently. This caused interruptions in production and affected overall plant performance.

Problem Statement

• The drive panel temperature was rising above the safe operating limit.

• High ambient and internal heat load were the main reasons.

• Drive panel trips occurred during peak operations, resulting in downtime.

• Conventional cooling (general AC or ventilation) was not sufficient to control localized panel heat.

• A dedicated, reliable cooling system was required.

Solution Implemented

After site study, the decision was made to install a Water-to-Air Heat Exchanger for the drive panel.

Key Features of the Solution:

1. Chilled Water Utilization:

   • Used chilled water from the same water-cooled chiller system.

   • No need for a separate cooling unit.

2. Cooling Coil with Circulation:

   • A cooling coil was placed inside the heat exchanger.

   • Chilled water circulated through this coil.

3. Air Cooling through Fan:

   • A fan blew hot panel air over the chilled coil.

   • The air cooled down and maintained uniform temperature inside the drive panel.

4. Control & Safety:

   • Digital temperature controller installed to maintain set temperature (~30–35 °C).

   • Alarm contact provided for safety interlock with the drive system.

5. Mechanical & Electrical Integration:

   • Coil connected with inlet and outlet of chilled water line using isolation valves.

   • Proper balancing valve installed for water flow adjustment.

   • Electrical wiring done for fan, controller, and alarm circuit.

Commissioning Process

• Water connection tested for leakage and pressure.

• Airflow verified across the coil.

• Controller set to maintain internal panel temperature between 30–35 °C.

• Alarm interlocks checked with the drive panel.

• Trial run conducted under full load conditions to ensure stability.

Results Achieved

• Panel temperature reduced from ~55 °C to 30–35 °C.

• Drive trips eliminated, ensuring uninterrupted operation.

• Cooling achieved without installing extra AC system, saving energy.

• Heat exchanger required minimal maintenance (only filter and coil cleaning).

• Overall reliability of the 220 kW water chiller improved significantly.

Customer Benefits

• Continuous production: No unplanned stoppages due to drive overheating.

• Cost savings: Used existing chilled water, avoiding additional power consumption.

• Drive protection: Maintained recommended operating conditions, improving lifespan.

• Simple solution: Compact, easy-to-maintain design.