Tag: Big Pharm

Implementing Energy Solutions that Don’t Jeopardize Your Plant’s Operations

Pharmaceutical manufacturers require 100 percent reliability in their chilled water plants to maintain product quality, ensure the validation of test results and eliminate manufacturing downtime.

Having the “correct” plant chiller sequencing set once is simply not enough to meet ongoing operational demands. On a daily basis, increased loads occur, weather conditions vary and unexpected maintenance issues happen. That’s why continuous, automated optimization is key.

Pharma facility directors can reduce energy costs even in the most demanding environments by tapping into tekWorx engineering expertise and adaptive control algorithms.

Pragmatic optimization solutions

At tekWorx, pragmatic solutions and proven chilled water plant optimization technology help companies minimize plant kW/ton while maximizing the use of existing equipment and limiting implementation downtime. Our CEO® solution, which utilizes the Niagara 4® platform, uses adaptive algorithms to continuously analyze real-time process variables and then automatically adjusts key parameter values for real optimization.

Easily integrated with any BAS, any mechanical configuration and any equipment make/model, the CEO® is the leading choice for effective, operator-free optimization.

Allergan chilled water plant optimization results

tekWorx recently worked with the Allergan Global Energy team to optimize their Irvine, CA, manufacturing site’s chilled water plant. While producing popular products such as BOTOX®, JUVEDERM® and LATISSE®, the company struggled to meet an installed capacity of 6,300 tons due to hydronic issues and the load shedding required on high temperature days.

After an initial assessment, the tekWorx engineering team devised a customized adaptive control strategy enabling the site to:

  • Maximize capacity using minimal kW/ton
  • Improve equipment utilization, which in turn improves redundancy
  • Decrease manual intervention
  • Reduce equipment wear and tear

The team integrated the CEO® solution with Allergan’s BAS to improve utilization and performance – all with minimal downtime. This pragmatic solution yielded tremendous bottom-line savings:

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Facility Bio

Situation

Solution


  • Irvine, CA

  • Three variable speed chillers and two constant speed chillers totaling 6,300 tons capacity

  • Distributed campus load with five secondary cooling zones

  • 11.5 cents blended utility rate


  • Installed capacity not achievable due to hydronic issues, load shedding required on high wet bulb temperature days

  • Enthalpy-driven cooling load

  • Chillers run when outdoor air could meet space temperature and RH requirements

  • Modifications over time created system and equipment imbalances

  • BAS control system functional, but did not provide optimization


  • Convert to full variable flow operation

  • Integrate supervisory Control Engine Optimization (CEO®) with existing BAS

  • Reset CHW supply temperature based on enthalpy

  • Efficiency-based chiller sequencing to improve utilization and performance

  • Reset zone DP setpoints to minimize flow and pump power

For more information

Discover how we put our Approachable Expertise® into action for other pharmaceutical companies by reading our online case studies for GSK and Merck. Then contact us to discuss how we can work together to reduce your energy and operating costs with no downtime.