Merck was desperate to improve the energy efficiency of their crucial S-6 chiller plant. The central plant was riddled with energy problems due to a wide range in the size and manufacturer of the chillers, convoluted piping and multiple control system with poor communication. Vast amounts of kilowatt hours and operator hours were wasted as plant operators manually adjusted equipment to meet water temperature setpoints without any trending to track demand or indicate problem areas. This was not a simple fix easily resolved by a treasure hunt. Merck knew where the inefficiencies were hidden; they just needed a partner that could simultaneously deal with mechanical and hydronic issues, and implement a truly optimized control system. They called tekWorx.
tekWorx converted Merck’s system to their patented Integrated Primary/Secondary® (IPS) system from a traditional Primary/Secondary design to remove its inherent inefficiencies. Additionally, they implemented a PLC-based adaptive control system to provide control sequences for energy optimization to collect data that would enhance maintenance capabilities and performance monitoring. After the installation, plant operators were no longer burdened with manual tweaks as they took advantage of remote energy monitoring with real time data which enhanced HVAC troubleshooting. While an energy analysis similar to a treasure hunt helped to identify the underlying issues within the plant, a more in-depth investigation was required for this effective energy optimization.
To find out how tekWorx has improved similar central plant conditions, check out our Results page.