Category: kW/ton

tekWorx Empowers JCI Client to Slash Operating Costs 68%



  • 480-bed private hospital
  • 75,000 ft2
  • Over 3,000 employees
  • (4) York chillers
  • 2,575 tons installed cooling capacity


  • Convert plant to Integrated Primary/Secondary® design
  • Reconfigure tertiary pumps to alleviate system pressure problems and eliminate wasted energy
  • Add VFDs to all building pumps to eliminate wasted pump energy
  • Design and install PLC based adaptive control algorithms to ensure maximum chiller loading, optimal control of all CHW pumps and proper balance of cooling towers and chillers


  • CEO ® system connected directly to JCI Metasys system via BACnet IP protocol, allowing tekWorx to gather real-time data on temperatures, flows, etc., and to fully control all plant equipment
  • Failover sequence developed and implemented to address control redundancy
  • No plant downtime during the course of this project
  • All major equipment remained in operation during commissioning


  • Manually operated system operating at 1.1kW/ton is now a real-time adaptive control system operating at .75 kW/ton
  • System experiences much less wear and tear
  • Operators are now freed up to perform other important tasks
  • CEO® User Interface has provides the staff with better insight into the system for diagnostics and trouble shooting

To learn more about this study and to see how tekWorx can help to optimize your plant, visit

Chiller Optimization vs. “Make it Work”

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Technological innovations have drastically changed the business environment over the past decade from the introduction of email and cell phones to tablet computers and drones. This trend has also made its way to chilled water plants with greater focus on increasing plant efficiency. Yet, chiller plant design has remained relatively unchanged since the mid-1970s. The primary/secondary system remains a “go-to” configuration since the strategy manages to sufficiently meet the demand of a building, but has no regard for efficiency. So, if it ain’t broke, why fix it? Energy savings- a lot of them. Chilled water not used by the load will always flow through the bypass valve and blend with warm water returning from the load. This blending raises return temperatures and makes the equipment work harder than necessary to maintain the setpoint. The inefficiencies caused by these central plant designs leave a lot of money on the table that can be captured with more innovative designs that reduce the electrical energy needed to produce chilled water.

Since these primary/secondary systems are still being designed and built today despite more efficient alternatives, tekWorx has developed an “Integrated Primary/Secondary” retrofit design (IPS®) to revitalize central plant efficiency with minimal capital expenditure. The IPS® approach eliminates bypass flow and therefore blending to control energy expenditures. Automation and controls work together, continuously monitoring demand, to ensure the best combination of system components are used to optimize plant kW/ ton. tekWorx focuses on controlling these central plants with minimally invasive procedures that deliver maximum energy savings.

To find out how tekWorx can optimize your chiller plant, fill out our Chiller Plant Evaluation Form.


Keys to Implementing Control Strategies Successfully

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Choosing to automate control systems in existing facilities is an extensive process that, when done properly, can reap long term efficiency and energy gains. Whether it’s an upgrade of an outdated system or converting a manual system to automated control, successful implementation is critical to improving building performance. Three industry best practices that enhance the success of control strategies are used by tekWorx to ensure seamless integration with the patented Control Engine Optimization (CEO®) system.

First, it goes without saying that knowledge is power. Without fully understanding the current system, there is no way in which to track improvement measures or understand how the changes in automation are impacting the ability of the system to meet demand. To empower clients, tekWorx focuses on performing energy audits and system blueprints to determine where inefficiencies may be hiding due to poor chiller plant design. Through this process, tekWorx is able to create pragmatic control strategies to lower plant kW/ton.

Secondly, plant managers need to identify opportunities for system integration that will provide additional functionality. Focusing on HVAC components is a logical place to start as cooling production has the greatest impact on energy consumption, especially with the unpredictable weather patterns of late. The core function of the CEO® is to automate all aspects involved in the chilled water production from the chillers, pumps, cooling towers, etc. to ensure that the best combination of system components are used to meet demand and minimize plant kW/ton.

The final consideration in automating plant systems involves linking building system data to business systems. Connecting the impact of the automation on bottom line financial statements is critical to evaluating the overall retrofit benefits. The use of real-time analytical tools is proven to increase energy efficiency as well as to optimize operations. The CEO® combines the data received from the overall BAS system and implements control strategies based on these real-time system parameters to reduce energy. The CEO® constantly works to cut central energy plant costs, increasing the availability of funds that can now be allocated to other important business functions.

To see how tekWorx can seamlessly optimize your system with the CEO®, check out our Results page.