Intelligent Cooling Optimization Elevates Virginia School District’s Energy Performance
Strategic chiller plant optimization with Xpress® technology sees major energy reduction without replacing control system.
33%
annual utility cost savings
152,000
kWh saved annually
location
Fairfax, VA
size
600 tons capacity
industry
K-12
the problem
Outdated System Struggling with Humidity Demands
A K-12 campus in northern Virginia was experiencing rising energy costs and inconsistent cooling performance due to an aging central plant system. The existing configuration operated inefficiently at 1.38 kW/ton with conventional scheduling and fixed setpoints that failed to address Virginia’s high-humidity conditions. This resulted in uncomfortable learning environments during shoulder seasons and excessive energy consumption during peak summer months. The district’s maintenance team lacked visibility into system performance, making it difficult to identify and address inefficiencies proactively.
the solution
Sophisticated Controls with Pragmatic Design
Following a comprehensive energy audit of the school’s multi-building campus, tekWorx engineers identified significant improvement opportunities in the traditional constant primary/variable secondary chiller plant. The team designed a Variable Primary Flow (VPF) hydronic conversion—eliminating unnecessary pumping stages while creating a responsive system capable of adapting to Virginia’s distinct seasonal patterns. he strategic approach centered on maximizing the existing infrastructure through intelligent system reconfiguration rather than costly equipment replacement.
With the improved hydronic foundation in place, the implementation team deployed the Xpress® adaptive control platform featuring:
- Humidity-responsive control strategies that optimize both temperature and moisture removal
- Dynamic load-based chiller sequencing to ensure efficient equipment operation
- Smart setpoint reset logic that responds to both outdoor conditions and zone requirements
tekWorx strategy provided a practical alternative to complete equipment replacement, offeringrapid paybackwhile minimizing capital expenditure from limited budgets.
the results
Seamless Implementation with Comprehensive Improvements
The implementation team worked closely with school administrators to execute the system improvements while school was in session, with no disruption to educational activities. Additionally, the project delivered impressive results across multiple dimensions:
- 33% Energy Reduction: Annual electricity consumption decreased by 152,000 kWh
- Increased System Resilience: Improved ability to maintain comfort during Virginia’s increasingly unpredictable weather patterns
- No Costly Replacements: Significant energy savings achieved with existing equipment and control system
- Operational Visibility: Facilities team gained comprehensive system insights through the Xpress® Energy Efficiency Dashboard
Intelligent hydronic design combined with advanced controls can deliver substantial energy savings without disrupting educational activities or replacing existing equipment. This project serves as a model for other educational facilities seeking to balance sustainability goals with operational requirements.