In 2016, after being purchased by FCA, it was announced the auto giant would invest $1.48 billion to again retool the Sterling Heights Assembly Plant (SHAP) site to build the next generation Ram 1500 and support the future growth of the Ram brand. The overhaul included an upgrade of the South paint shop and its Energy Center which houses chillers, hot water generators, pumps, purified water equipment, non-potable water supplies and associated equipment.

tekWorx blue ribbon was presented for the Xpress® control and optimization solution that optimizes the chilled water equipment at the SHAP South Energy Center. tekWorx Xpress® optimization algorithms continuously adjust equipment sequences and key setpoints based on parameters related to process requirements and outdoor air temperature.  This ensures maximum system efficiency in real‐time while maintaining cooling requirements at the lowest total kW per ton.

Xpress®, combined with the energy impact of YORK® YMC² magnetic-bearing chillers, has resulted in an average annual total system efficiency of 0.42 kW/ton over the last three years. Xpress® optimization mode saves the Energy Center nearly 3,000,000 kWh annually and reduces yearly energy expenses by approximately $175,000.

About the ASHRAE Technology Awards

The ASHRAE Technology awards are an international competition that recognize outstanding achievement in the design and operation of energy efficient buildings. Winning projects incorporate ASHRAE standards for effective energy management and indoor air quality and serve to communicate innovative systems design.

Visit this link for more information on the ASHRAE Technology Award and this year’s list of winners. The SHAP optimization project will be featured in ASHRAE Journal’s August issue.

Selecting Chilled Water Pumps for Efficiency

First and foremost, properly sizing and selecting pumps is crucial to sustained energy savings. Pumps should be selected to meet the requirements of a system as a whole. Why? The energy consumption required for any system depends on the flow rate of the entire system. By reviewing the entire system, the right pump for the application can be selected and the proper control methodologies can be implemented that best match pump performance to the needs of the system.

Chilled Water Pump Optimization

Chilled water pumps consume significant amounts of electricity when operating. Monitoring pump efficiency therefore requires an accurate assessment of actual consumption including such parameters as system flow, head, pump, motor and/or drive efficiency, and run time. In existing systems, the energy requirements can be measured over time as a benchmark to aid in identifying where energy consumption can be optimized.

Because system pressure varies with flow rate, it is important to understand the control sequence that is maintaining the flow and pressure in a system. Why does this matter? The way the pumps are controlled is a key component of HVAC optimization. Many facilities utilize pumping power that is not needed via inefficient control strategies, such as running chilled water pumps at constant speed. Optimization solutions like tekWorx Xpress® will determine the number of chilled water pumps and condenser water pumps necessary to deliver the required volume of water at the lowest total power per unit of cooling production (kW/ton).  With Xpress®, this algorithm will often operate more pumps at lower speed rather than less pumps at higher speed to minimize pumping energy, per pump affinity laws. 

Chilled Water Pump Optimization and Maintenance

Routine checkups and maintenance are necessary to ensure chilled water pumps are in good working order and functioning efficiently. Best practices include:

• Monitoring pump vibration
• Checking mechanical seals for leaks.
• Monitoring bearing lubrication and temperature
• Checking water pH and clarity
• Monitoring pump and motor shaft alignment to prevent uneven wear of couplings

Proper maintenance of chilled water pumps helps to build immunity against unnecessary wear and tear on a system while routine checkups help to ensure pumps will operate as designed for many years.

Looking for ways to optimize cooling towers? Manufacturing companies spend billions of dollars each year for the fuel and electricity that keep their facilities running. Energy saving products, designs and systems are more widely available than ever before. However, with Heating, Ventilation and Air Conditioning (HVAC) consuming the largest amount of a plant’s energy bill, efficiency efforts are best focused in that area. One such subset is in cooling towers, essential to control suspended solids and algae growth.

Cooling towers cool water through heat transfer and evaporation. With a loss of 1% water for every 10 degrees of cooling required, the evaporation factor can be very significant. When evaporation occurs, scale is left behind that can interfere with cooling tower efficiency and require expensive maintenance or acid cleaning.

Industrial plants typically contain equipment which requires both open evaporative and closed cooling water systems, making well-maintained cooling tower chemistry essential to plant reliability and efficiency. As we get into the warmer months of the year, the ambient heat of the summer months will detract from the cooling capacities of these towers if they are not kept in good shape.

This makes them “fatigued”, putting a strain on system equipment and the water it provides devices such as heat exchangers, production machinery and HVAC systems will be less able to draw off heat. In industries where a cooling tower supports critical processing machinery, HVAC system or even refrigerators and freezers, even a small dip in cooling power can cause extensive downtime or even product losses.

Over time, the leaving-water temperature of a neglected cooling tower will rise. For every 2-degree F increase, the equipment’s energy costs will also increase—by up to 6%.  However, simple maintenance techniques can optimize cooling towers and save facilities up to 15% on its electricity costs.  Routine preventive maintenance also can help conserve water, extend the operating life of your cooling equipment, and keep energy and equipment costs low.

4 Areas to Investigate to Ensure Cooling Towers are Operating at Peak Efficiency

1. Monitor Cooling Tower Fill

The purpose of the fill, also called wet deck or surface, is to maximize the contact between the air and the water, encouraging evaporation. Fill is covered in a textured pattern, usually ridges or wrinkles, so that when pieces of the fill are placed together, they leave open spaces for water and air to travel.

This fill should be serviced or replaced in cooling towers to avoid fouling that will prevent sufficient air volume necessary for the system’s water to dissipate heat efficiently. Fouling can also make the fan and motors work harder, adding significantly to energy costs.

2. Cooling Tower Equipment Selection  

When choosing a HVAC or industrial cooling tower, keep in mind that cooling efficiency is affected when aggressive chemical maintenance solutions are limited due to the risk of harm and damage to metal surfaces. This makes them less efficient and susceptible to maintenance and unscheduled shutdowns. Further, having to limit potent chemicals used to remove biological growth from water can produce fouling build-up inside the cooling tower which affects cooling efficiency.

Because plastic cooling towers are impervious to residual salts, the tower cannot be damaged and fill material can be cleaned up by most aggressive de-scalers which goes a long way toward efficiency and avoiding unexpected replacement expenses.

3. Frequent Cooling Tower Inspection  

Daily, weekly and monthly system monitoring will keep energy usage and costs down while ensuring cooling system are working at their optimal level.   Frequent visual inspection of your cooling system’s fans, motors, belts and pumps is an effective way to ensure that your systems are running at their highest efficiencies. Loose belts or improperly working fans will prevent smooth flow through the system and result in reduced efficiencies and higher operational costs.

If water temperatures increase even a small amount, the return water from the towers to the chillers will cause the chiller to work harder, resulting in increased costs and a reduced cooling effectiveness. Regular inspection of basins, drains and nozzles will also prevent the buildup of minerals, debris and dirt that will clog the system,  increasing energy consumption and reducing overall system efficiency.

4. Optimizing Cooling Tower Control 

Inefficient chilled water plant controls are often associated with poor cooling tower performance and investments here can greatly improve overall HVAC efficiency.   Some solutions, like tekWorx Xpress® , can act as an early warning system, sending emails or texts to staff when equipment such as a fan, pump or chiller is operating outside expected parameters.  

tekWorx Xpress® algorithms optimize cooling towers by continuously adjusting cooling equipment operation and key setpoints based on such parameters as occupancy level and outdoor temperature to maximize the system efficiency in real‐time. This is done while maintaining comfort cooling needs.  Xpress® optimizes overall cooling system energy consumption via several of its patented algorithms, including:

• Condenser Water Temperature Optimization: Determines the equipment operating parameters that will produce the optimal condenser water temperature that will minimize total power consumed by the chiller and cooling towers.  This algorithm balances auxiliary equipment power with chiller power to operate the chillers most efficiently based on ambient conditions and load.

• Adaptive Tower Sequence Optimization: This module will sequence cooling tower isolation valves (cells) on and off to flow water over the maximum amount of cooling towers without falling below the minimum flow rate of the associated tower cells.

To optimize cooling towers and associated plant equipment requires diligent maintenance, proper equipment selection and the right control strategy to permanently improve overall HVAC efficiency.

Start at the Top

The most successful approach to creating an energy efficiency plan begins with a commitment from management. This typically starts with simple statement of what is to be achieved such as reducing carbon emissions or being strong environmental stewards. Once this essence is established and agreed upon, endorsement and internal publication of the energy policy begins. Endorsement by senior management, recognizing and praising energy-related achievements and consistent communications related to the energy motto are key for continued success.

Responsibility

Once an energy efficiency plan is in place, a leadership team should be appointed that represents a solid cross-section of the organization in terms of job function and geography. This team is responsible for both establishing reduction metrics and tracking measurable energy reduction goals such as percentage reductions or absolute reductions, water- and sewer-use savings or increased equipment production capacity and reliability.

Accountability

Energy efficiency plans need to be supported by data. The two basic types of energy-saving-initiative measurements are metered and calculated. In a perfect world, all energy savings would be metered. The cost of metering the exact savings can be cost prohibitive to implement. Conversely, calculated savings had an added complication of making adjustments for effects of year-to-year production activity, weather-related energy usage and/or other variables to be truly accurate.

One solution to this dilemma is an energy monitoring system. For example, tekWorx Xpress® monitors energy performance, equipment operation and associated energy costs daily, month and yearly and presents this data in an easy-to-read dashboard. Xpress® also offers real-time energy performance comparison and efficiency ranking, providing instant insight energy use a portfolio’s collective energy profile and how each site ranks relative to the efficiency of the others. 

HVAC systems are in charge of keeping temperatures comfortable, humidity consistent , and indoor air quality high. Often times, however, airside optimization is not considered in facility controls.

As much of the energy and cost that goes into powering HVAC is lost to waste, these three smart airside optimization strategies can help facilities can realize significant HVAC energy savings.

Airside Optimization and Air Filtration Systems

In order for HVAC system to operate correctly and deliver proper indoor air quality (IAQ), air filter maintenance and monitoring are essential. Most BAS systems monitor for air pressure drops outside of normal ranges. When this occurs, it often means that the air filter is clogged and/or installed improperly and should be changed. Dirty filters overwork HVAC systems by restricting air flow leading to poor indoor air quality, HVAC maintenance issues and increased repair costs.

Airside Optimization: Heating and Cooling Ducts

Commercial heating and cooling systems are connected to points throughout a facility by the ductwork. Consisting of a network of large pipes, this ductwork provides a pathway for conditioned air to travel from heating and cooling equipment to the insides of a commercial building.  Any problems in a facility’s duct system — broken seals, loose or missing sections, detached pipes, or damaged ducts — can cause substantial air leaks that will result in lost energy and wasted operating dollars. Duct sealing and careful inspection and appropriate repair of the ductwork will prevent these problems. Connections between sections of ductwork should be properly sealed with mastic, a specialized rubbery compound designed especially for ducts. Metal tape can also be used. Connections can also be mechanically fastened with sheet metal screws. Standard duct tape should be avoided because the adhesive can dry out and cause the tape to fall away.

Airside Optimization and AHU Monitoring

In commercial buildings, all air handlers are built and installed with an outside air intake and damper.  This outside air intake and damper has a large effect on both the energy use of a building and the indoor environmental quality (IEQ) of a building. By optimizing air handling units (AHUs), significant energy savings can be achieved.

Normally, air handlers cool or heat a mix of return air from the space it is conditioning and outside air that is required for proper IEQ. When the outside air dampers let in more outside air than required by the building code,  the air handler will use more energy than needed.  Conversely, dampers can let in too little air. This often happens when the outside dampers fail in a position where they are completely closed and do not allow any outside air into the air handler.  Advanced airside optimization solutions ensures these conditions are constantly being monitored.

Optimizing AHUs requires real-time monitoring of static pressure and supply air temperature setpoints. Sensors throughout the facility feed temperature and humidity data to a BAS or other control device and algorithms then determine optimal heating and cooling requirements, sending these efficiency setpoints back to the air handlers. Not only does this approach save energy dollars but helps ensure better occupant comfort.

tekWorx real-time airside optimization by continuously and automatically minimizing the power required for air distribution and delivery. These proven adaptive control techniques optimize air pressure, flow and temperature (system and zone) while maximizing economization mode and meeting desired space conditions.

The most common chiller failures are caused by compressor, electrical, or motor problems.

Compressor Maintenance to Optimize Chiller Performance

Compressor failure can be the result of any number of factors and is often attributable to problems elsewhere in the system. One simple routine task to prevent compressor failure is checking strainers and filters for dirt and debris and ensuring the compressor and pumps are appropriately sized for the load.

Eddy current testing, at a suggested interval of every three years, reduces the risk of chiller failure caused by condenser evaporator tube leaks or failures. Chiller tubes undergo daily stress as part of their normal operation which can allow rust and corrosion to take hold. Additionally, these rust particles can trickle into the evaporator tubes of the chillers, leading to corrosion that damages the compressor itself.  An eddy test determines the wall thickness of the chiller tubes and can detect possible pitting, cracks and bulges that can precipitate tube leaks. Identifying issues before a major problem occurs prevents downtime and expensive replacement costs.

Chiller Electrical Maintenance to Optimize Chiller Performance

Electrical issues in the chiller plant can be caused by a host of issues including wires rubbing equipment frames or condenser fans not working appropriately.  Electrical overload conditions will cause motors to draw in more current to maintain torque and can lead to overheating and damage to winding insulation.  Regular attention to amperage draw, voltage, and contactors can avoid such issues.

Chiller Motor Maintenance to Optimize Chiller Performance

Chillers, pumps and tower fans use motors to move water and air or compress refrigerant. The failure of any of these motors threatens the operation of the entire chiller system. There are many reasons why motors fail, but three fairly simple, non-damaging tests can avoid a world of headaches when performed consistently.

• Oil Analysis: Regularly scheduled analysis of your chiller’s oil is a valuable aid in assessing internal mechanical condition. Oil comes in contact with many important internal components and can therefore hold valuable information about chiller health. An oil analysis will indicate whether there is moisture, acid, corrosion, bearing wear, impeller rubbing, or other equipment problems present. When an oil analysis reveals the presence of wear, a possible bearing or motor failure can be imminent, and a vibration analysis is recommended. The combination of these assessments will typically identify the failing component.
• Vibration Analysis: Every piece of HVAC equipment with rotating components has its own vibration signature. Any change in this signature can be used as an accurate means of identifying developing problems with chiller bearings, impeller imbalance, or open rotor bars in the motor. Vibration analysis should be performed on a regular basis to build a baseline and trend which can significantly aid in avoiding unplanned downtime and replacement costs
• Motor Insulation Resistance: Insulation problems on motors and drives are typically caused by improper installation, environmental contamination, mechanical stress, or age. Insulation tests should be performed on all chilled water system motors to monitor motor health. These assessments measuring the winding resistance. A low resistance indicates that the winding is deteriorating and indicates potential failure. Insulation-resistance trending can ensure that any changes are readily addressed.

Monitoring Chiller Performance

Selecting quality equipment and performing regular maintenance specific to the needs of each unit ensure a long and efficient life cycle. To protect such investments, the remote monitoring of chillers and cooling system can significantly aid maintenance and service efforts.

Chilled water system monitoring, like that of the Xpress® Energy Optimization Dashboard, provides facilities teams with real-time energy data for all chilled water equipment. Understanding how energy is used can help quickly identify energy waste and equipment problems, as well as overcharges and errors on energy bills. Xpress® also acts as an early warning system, sending emails or texts to staff when equipment such as a fan, pump or chiller is operating outside expected parameters.

It is no surprise then that hospital operations teams are continually seeking to improve energy efficiency and reduce operating costs.  Hourly hospital energy consumption data from the Orlando Utilities Commission underscores that cooling, ventilation and lighting represent the largest opportunities for reducing electricity costs in healthcare facilities. Let’s take a look at how to reduce spending in those areas.

Ventilation & Hospital Energy Savings

The large quantity of outside air necessary for proper ventilation requires an increased amount of energy to condition. While ventilation can limit the spread of airborne pathogens throughout a healthcare facility, these higher ventilation rates come at an increased energy cost.

Many hospitals ventilate spaces as if they were occupied at full capacity. For non-critical spaces that have fluctuating capacity like indoor parking garages, lobbies, and cafeterias, energy savings can be realized by reducing ventilation when these spaces are not full. A demand-controlled ventilation (DCV) system senses the amount of carbon dioxide in the space’s return airstream and uses it as an indication of occupancy. It then adjusts how much outside air is brought into the space based on the current occupancy level. By modulating this process, DCV reduces the amount of outside air that must be heated or cooled and the amount the fans must run to move that air.

DCV systems rely on occupancy to reduce the operating speed of the supply and exhaust fans when rooms are unoccupied. When there are issues with this equipment that go undetected, however, energy is used in excess.  Periodical recommissioning can ensure that dampers, actuators, or control cycles aren’t getting  stuck open or failing to operate correctly.

Lighting & Hospital Energy Savings

The lighting demands of hospitals are complex due to their round the-clock nature. Both low-tech and high-tech solutions, however, exist for lighting controls that can greatly reduce energy costs.

One simple, low-tech reduction solution is lighting awareness campaigns that train staff to turn off lights when rooms are not in use. De-lamping is an additional, lower-cost way to reduce energy. As the name suggests, it’s done by removing unnecessary light bulbs and fixtures in areas that are producing greater-than-needed illumination. De-lamping in areas of excessive illumination immediately reduces energy consumption while also decreasing cooling load needs in warmer months. Further, replacing traditional bulbs with LEDs can save upwards of 50% percent of the energy costs of using traditional light bulb.

High-performance lighting systems can significantly reduce energy usage by ensuring electric lighting is used only when necessary. Installing occupancy controls, dimmers, and daylighting controls in offices, break rooms, storage rooms, and restrooms can have a dramatic affect in reducing lighting electrical use.

Space cooling & Hospital Energy Savings

While ventilation and lighting improvements can reduce energy costs, chiller plants are the single largest consumer of energy in most health care facilities.  Hospital cooling, therefore, bears the brunt of utility usage and optimizing the chiller plant is one of the greatest means of short and long-term reduction of energy use.

Optimizing the cooling system ensures that hospital conditioning requirements are being met at the lowest possible cost (or kW/ton). A system, however, must be designed for optimization-new equipment or analytics packages will have an energy impact but fall short of realizing optimization savings.

To assess a hospital’s candidacy for optimization savings, an audit should be performed to assess how the cooling system and equipment is being used, how the hospital’s various systems and machines either do or do not work together, how current operation strategies are impacting energy performance, and what pragmatic solutions could be implemented that will both reduce consumption and pay back quickly.

Xpress® & Hospital Energy Savings

One such solution is tekWorx Xpress®, a combination of adaptive control algorithms and Tridium Niagara N4 hardware that optimize a hospital’s chilled water plant equipment (air-handling units, fan coils, chillers, cooling towers, etc.) in real-time. These optimization algorithms continuously adjust equipment sequences and key setpoints based on such parameters as occupancy level and outdoor temperature to continually maximize the system efficiency while maintaining space cooling conditions throughout the hospital, including operating rooms. An integrated dashboard allows facilities staff to monitor the overall efficiency of the chilled water system from anywhere at any time.