Chiller Plant Optimization Yields $386,000 Utility Rebate
Pharma giant maintains cooling production during a major hydronic system and adaptive control system update, saving over 5 million kWh annually and earning a large PECO utility rebate.
Facility Bio
- West Conshohocken, PA
- Pharmaceutical R&D campus
- Critical 24/7 operations
- Nine (9) chillers, varying size & type
- 10,600 tons cooling capacity
- 1,200 ton free cooling HEX
Situation
- Corporate “Climate Change” program identified savings and rebate opportunity
- New utility contract estimated to increase rates ~50%
- Constant flow hydronic design
- Manual operation to meet current cooling load
Solution
- Detailed implementation plan to maintain production
- Convert to full variable flow
- CHW pump VFDs
- Modulating bypass valve
- Evap valves for different chiller DPs
- Condenser pump and cooling tower VFDs
- Integrate PLC-based Control Engine Optimization® system
Results That Exceed Client Expectations
Financial Savings
- $386,000 PECO utility rebate
- $425,000 in annual energy savings
- 4-year payback before rebate
Energy Impact
- 5,130,000 kWh saved annually
- .41 kW/ton efficiency improvement
Operational Benefits
- Fully automated system
- Staff free up for other tasks
- Increased cooling reliability
- Significantly lower system pressure cut AHU valve maintenance
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