Tag: chilled water optimization

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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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.

Energize Your Bottom Line with a Comprehensive, Complimentary Energy Audit

When hearing the phrase energy audit, do you automatically think a) we did that years ago, or b) it’s not in the budget for this year?

Consider what it would mean for your corporate bottom line if a free energy audit reported that your company could realize an annual savings of 10-50 percent in energy costs? Well-prepared energy audits reveal a range of solutions, while requiring only a minimal investment of corporate time.

The tekWorx energy audit process

At tekWorx, our engineers start the no-risk audit process by performing an onsite evaluation – inspecting the chilled water system piping, equipment and controls, viewing design plans and talking to operators. In addition, the tekWorx team reviews plant chiller logs and bin data to help acquire an overall energy-efficiency baseline.

tekWorx offers a comprehensive energy audit to cut 10-50% in energy costs

Following the information-gathering phase, tekWorx engineers will provide a chilled water (CHW) system performance assessment for your unique plant detailing:

  • How the current CHW system consumes energy, along with a comparison to industry best-practice targets
  • Short, medium and long-term Energy Conservation Measures (ECMs)
  • Adaptive control strategies for minimizing plant kW/ton
  • Projected investment for savings and a payback target
  • Applicable energy rebates and associated calculations

tekWorx delivers our customers a unique blend of Approachable Expertise®, increasing operational efficiency and reducing energy costs while designing pragmatic solutions to meet their unique needs. As part of the recommended solution, our team seeks to improve energy efficiency by maximizing current equipment instead of making additional capital expenditures.

 For more information

To see how tekWorx turns energy audits into real-world results, read our online case studies. Then fill out our Chiller Plant Evaluation Form or contact us to initiate the free, comprehensive audit process.

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How tekWorx Helped a Major Pharmaceutical Site Save $542,000

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.

How Professor Pump Became a Guiding Force at tekWorx

You sometimes meet people and immediately understand their impact will be felt far and wide for years to come.

Our co-founder Burt Rishel was one of those people. He made his mark in design,Burt Rishel, Co-Founder engineering and writing while influencing those around him with his intelligence, heart and dedication.

A gifted engineer and a captain of the Army Air Corps, his first major achievement was as a principal designer for the CG-10A glider, which became the first Assault Cargo aircraft. Then he found his true professional love – pumping systems –
which earned him the nickname Professor Pump.

Professor Pump first founded Systecon, and then helped launch tekWorx in 2000. He loved designing pumping systems and helping companies operate more efficiently. His work took him across the country, serving as a consultant for the chilled water systems at the Denver International Airport, the National Institute of Standards and Technology and the National Institutes of Health.

A prolific writer of technical articles, he also wrote two influential books: “HVAC Pump Handbook” and “Water Pumps and Pumping Systems.”

“At tekWorx, we are indebted to our co-founder, friend and inspiration. His knowledge made us a pioneer in the field. His mentorship molded us. His customer-first focus motivated us,” says Managing Partner Mike Flaherty.

Burt passed away in August 2013, leaving a legacy that all of us at tekWorx strive to live up to every day.

For more information about tekWorx

Discover the next generation of Professor Pumps. Contact tekWorx today with your energy-saving questions and see how we can partner together to achieve an effective chiller plant optimization solution. Plus, follow us on Facebook, Twitter and LinkedIn for our most up-to-date news and events.