AbbVie Saves $542,000 Annually with Xpress® Optimization
tekWorx leveraged existing infrastructure to deliver a dramatic increase in system efficiency and savings for one of AbbVie’s largest domestic plants — all while maintaining uninterrupted chiller plant operations.
4,700,000
kWh saved annually
6
month payback
location
Irvine, CA
size
6,300 tons capacity
industry
Pharma
the problem
Multiple Operational Challenges Limited Plant Performance & Efficiency
Despite adequate installed capacity, hydronic issues forced load shedding during high wet bulb temperature conditions. The enthalpy-driven cooling load created additional complexity, while chillers frequently operated unnecessarily when outdoor air conditions could have satisfied space requirements. System modifications over time had introduced equipment and hydronic imbalances throughout the plant. While the existing BAS control system remained functional, it lacked the sophisticated optimization capabilities needed to address these interconnected challenges and maximize plant efficiency.
the solution
A Comprehensive Optimization Strategy Anchored on Existing Infrastructure
The system was converted to full variable flow operation, significantly improving hydronic performance and eliminating load shedding issues. By integrating the tekWorx Xpress® platform with the existing BAS, the facility gained sophisticated control capabilities without requiring a complete system replacement. The optimization strategy included:
- Dynamic chilled water supply temperature reset based on enthalpy conditions, ensuring optimal efficiency while maintaining space conditions.
- Efficiency-based chiller sequencing was implemented to maximize utilization and improve overall plant performance.
- Zone differential pressure setpoints were optimized through continuous reset, minimizing flow requirements and reducing pump power consumption while maintaining reliable cooling delivery.
The project implementation exceeded facility requirements by achieving a six-month payback while maintaining uninterrupted chiller plant operations throughout the optimization process.
the results
From Underperforming to Leading the Pack
The optimization strategy delivered substantial financial and operational benefits for the facility. The project achieved $542,000 in annual utility cost savings, with an additional $250,000 secured through utility rebates. These combined savings resulted in an impressive payback period of just under six months. The environmental impact was equally significant, with annual energy savings of 4,700,000 kWh.
Beyond the quantifiable benefits, the enhanced automation reduced the need for manual intervention, improving operational efficiency. The optimized chilled water temperature control significantly reduced reheat costs, while improved equipment utilization increased overall system redundancy. Together, these results transformed an underperforming chiller plant into a model of efficiency and reliability.