University Cooling System Upgrade Slashes Energy Use While Expanding Capacity

University Cooling System Upgrade Slashes Energy Use While Expanding Capacity

1,000,000

$75,000

scale

44 Buildings

size

4,500 tons capacity

industry

Higher Ed

the problem

Outdated Infrastructure Limiting Growth

The 9,000-student campus was struggling with an outdated, inefficient cooling system that served 44 buildings through a central chilled water plant. With three Trane constant speed chillers providing 4,500 tons of cooling capacity, the traditional primary-secondary hydronic system operated for approximately eight months each year. As demands grew, the aging infrastructure showed critical weaknesses that threatened both operational stability and future campus development:

  • Low chilled water delta-T and high kW/ton indicated significant inefficiency
  • Lack of coordination between buildings and central plant wasted energy
  • Outdated Andover control system offered no optimization capabilities

the solution

Seamless Integration Without Disruption

tekWorx was selected to implement a comprehensive upgrade that included hydronic modifications and optimization software. First, the mechanical system inefficiencies were addressed by converting to full variable flow using the innovative Integrated Primary-Secondary® (IPS®) design, which mimicked Variable/Primary efficiency while allowing all existing pumps and piping to remain in place. Second, Xpress® adaptive optimization platform was deployed to intelligently managed system performance in real-time. Finally, these new systems were integrated with the existing campus Building Automation System to establish seamless coordination between building requirements and central plant operations.

Most importantly, the entire implementation proceeded with zero disruption to daily campus operations, allowing classes, research, and administrative functions to continue uninterrupted throughout the upgrade process.

This comprehensive approach delivered three key advantages:

  • Implementation completed during regular maintenance window with zero academic or administrative disruption
  • The IPS® solution required only minimal sensors and valves instead of costly piping modifications
  • Direct integration with existing controls eliminated the need for extensive infrastructure replacement

“tekWorx delivered substantial energy savings without disrupting campus operations, using practical solutions that worked with our existing infrastructure.”

Assistant Director, Facilities

the results

Immediate Savings, Long-Term Sustainability

Xpress® delivered immediate financial and operational benefits, reducing energy costs while significantly increasing the available cooling capacity needed for the campus expansion plans. By improving system efficiency, the tekWorx Xpress® solution effectively created additional cooling capacity without requiring new chillers or major infrastructure investments. The campus achieved $75,000 in annual energy savings with just a two-year project payback period. Other key savings areas included:

  • 1,000,000 kWh saved annually, equivalent to removing 150 cars from the road
  • Efficiency improved by 0.25 kW/ton, unlocking over 20% additional cooling capacity for future campus expansion
  • Reduced pump wear and maintenance costs through optimized operational ranges

Xpress® transformed campus operations by delivering both immediate financial returns and sustainable long-term capacity benefits. This strategic implementation demonstrates how the combination of advanced software and hydronic expertise made a critical difference, solving multiple infrastructure challenges simultaneously while advancing environmental goals.


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