Chiller Plant Optimization Yields $386,000 Utility Rebate

Pharmaceutical giant maintains cooling production during a major hydronic system and adaptive control system update, saving over 5,000,000 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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