tekWorx recently worked alongside the Allergan Global Energy team to optimize chilled water plant operations at their Irvine, CA manufacturing site. The makers of such well-known products as BOTOX®, JUVEDERM® and LATISSE® were struggling to meet an installed capacity of 6,300 tons due to hydronic issues and the load shedding required on high wet bulb temperature days.
Modifications had also been made over the years that caused system and equipment imbalances that negatively impacted the site’s energy profile. While a BAS control system was in place and functional, it did not provide any optimization.
After an initial assessment of the plant’s operating profile via data submitted in a Chiller Plant Optimization Evaluation, tekWorx engineers devised a customized adaptive control strategy that would allow the Irvine site to:
- Maximize capacity using minimal kW/ton
- Improve equipment utilization, thereby improving redundancy
- Decrease manual intervention
- Reduce equipment wear and tear
Because the site already had a functional BAS system, tekWorx took a pragmatic approach by integrating our supervisory CEO® with Allergan’s existing system instead of replacing it completely. tekWorx engineers converted the plant to a full variable flow, reset CHW supply temperature based on enthalpy, and implemented efficiency-based chiller sequencing to improve utilization and performance, all with minimal downtime.
Our Allergan results
tekWorx solution enabled Allergan to minimize pump flow and power consumption, ensuring that the optimal set of equipment is always in operation. But what does that really mean for the bottom line? As you can see, the results speak for themselves:
- 5 cents blended utility rate
- $542,000 annual utility cost savings
- $250,000 utility rebate
- ~6-month payback
- >4,700,000 kWh saved annually
The tekWorx results don’t end here. Check out our case studies for more happy bottom lines in a wide range of industries.
For more information
To see how tekWorx can put our Approachable Expertise to work for you, contact us with your chiller control and optimization questions. You can also follow us on Facebook, Twitter and LinkedIn for our most up-to-date news and events.