6-Month Payback: Pharma Plant Saves $542K Annually with Xpress® Optimization
tekWorx solutions utilized existing infrastructure for increased system efficiency and savings.
Facility Bio
- Irvine, CA
- Three variable speed chillers and two constant speed chillers totaling 6,300 tons capacity
- Distributed campus load with five secondary cooling zones
- 11.5 cents blended utility rate
Situation
- Installed capacity not achievable due to hydronic issues, load shedding required on high wet bulb temperature days
- Enthalpy-driven cooling load
- Chillers run when outdoor air could meet space temperature and RH requirements
- Modifications over time created system and equipment imbalances
- BAS control system functional, but did not provide optimization
Solution
- Convert to full variable flow operation
- Integrate supervisory Control Engine Optimization (CEO®) with existing BAS
- Reset CHW supply temperature based on enthalpy
- Efficiency-based chiller sequencing to improve utilization and performance
- Reset zone DP setpoints to minimize flow and pump power
Results That Exceed Client Expectations
Financial Savings
- $542,000 annual utility cost savings
- $250,000 utility rebate
- Just under a 6-month payback with the rebate
Energy Impact
- >4,700,000 kWh saved annually
Operational Benefits
- Improved automation means less manual intervention
- Improved CHW temperature control reduces reheat load and cost
- Improved equipment utilization increases system redundancy
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