Major Data Center Avoids $3.5M in CapEx with Xpress® System
A Tier 3 data center faced with expensive expansion needs found an innovative solution that recovered hidden cooling capacity while reducing operational costs.
$3,500,000
cap ex avoidance
4.7M+
kWh saved annually
location
North Bergen, NJ
size
3,600 tons capacity
industry
Data Center
the problem
A major Tier 3 data center in the Northeast US needed to expand cooling capacity to accommodate growing server loads. The traditional solution—adding more chiller modules to their modular packaged plant—exceeded both their budget and timeline constraints. Their existing 3,600-ton system was operating inefficiently with low delta-T (ΔT) and excess flow, leaving significant capacity unusable.
the solution
tekWorx implemented their Xpress® system, a comprehensive optimization approach that transformed the data center’s cooling infrastructure. The solution leveraged advanced algorithms to dynamically manage system operations based on real-time conditions:
The implementation included several key components:
- Conversion from traditional primary-secondary pumping to full variable flow architecture
- Implementation of Xpress® algorithms that continuously:
- Optimize chiller sequencing and loading patterns
- Balance water flow rates to maximize ΔT
- Adjust setpoints dynamically based on actual cooling demand
- Strategic system tuning to minimize overall kW/ton across the entire plant
This intelligent approach not only recovered previously unusable chiller capacity but also provided the perfect opportunity to upgrade the facility’s control systems to full N+1 redundancy without any operational downtime.
We were looking at spending $3.5 million on new chillers when the tekWorx team came in and said, ‘You don’t need to buy all that equipment.’ They were right. Their Xpress® System not only saved us that massive capital expense but gave us this incredibly robust control system with full redundancy.
VP, Engineering
the results
The optimization strategy delivered exceptional financial and operational returns, far exceeding expectations. The data center avoided $3.5 million in capital expenditure that would have been spent on additional chiller sets, while also achieving $167,000 in annual energy savings with a rapid one-year payback period. The environmental and efficiency impacts were substantial:
- 4.7 million kWh reduced annually
- 0.31 kW/ton efficiency improvement
The operational benefits were equally impressive, with zero integration downtime during implementation and an upgrade to full N+1 redundancy in the PLC control system, significantly enhancing the facility’s reliability and resilience while maintaining continuous operations.