Tag: energy savings

Automated Optimization vs. Analytics: What’s the Best Path to Optimization?

Analytics packages seem to have it all. At first glance, integrated dashboards provide a snapshot of operational processes, metrics and key performance metrics (KPIs).

Unfortunately, analytics as an actual cost reduction tool in chilled water systems are limited unless a human takes action on this information to adjust operations. Optimizing the efficiency of dynamic systems, such as a chilled water plant requires action, ideally continuous action, that does not rely on manual intervention.

The optimization spectrum

 

The various levels of efficiency improvements

Of the four basic levels of efficiency improvements in use today, optimization and analytics are the most discussed. While they are complementary, they are not the same. Analytic and model-based strategies simply suggest edits, not action. Without automation, analytic software cannot optimize dynamic settings like a chilled water plant.

tekWorx automated optimization

The Approachable Experts™ at tekWorx can help your team go beyond analytics to optimize the efficiency of your dynamic system.

Our automated optimization solutions maximize the use of your existing mechanical equipment and controls to significantly improve plant performance. Using adaptive algorithms to continuously analyze real-time process variables, key control parameters are automatically adjusted to minimize plant kW/ton without any human intervention.

For more information about the differences between chilled water plant efficiency improvement models, download our “Go Beyond Analytics to Optimization in Chilled Water Systems” white paper.

Discover the differences in chilled water plant efficiency improvement models in our Go Beyond Analytics in Chilled Water Systems white paper


Learn more about our CEO®  family of solutions

Discover how tekWorx puts our Approachable Expertise® into action by reading our online case studies. Then contact us to discuss how we can work together to improve the energy performance of your unique plant.  Whether you’re looking for a self performance solution or a comprehensive, commissioned solution, we have your optimization needs covered.

Follow us on LinkedIn for the most up-to-date news and events.

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:

Case Study Icons-10Case Study Icons-08

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.

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.

Follow us on LinkedIn for the most up-to-date news and events.

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.

Chiller Optimization vs. “Make it Work”

If it ain't broke, don't fix it-resized-600

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.