Chiller Optimization Improves Lab Expansion Project ROI

ChillerOptimization Savings Fund Expansion Project

Merck integrated tekWorx adaptive control and optimization solution with a planned lab expansion, using the energy savings and utility rebate to help justify the total project.

Facility Bio

  • S-6 Plant in Summit, NJ
  • New 800,000 ft2 R&D lab
  • 7 chillers of varying size, type and age
  • 7,800 ton cooling capacity
  • 24/7 critical operations


  • Unreliable cooling production required frequent manual intervention
  • Traditional Primary- Secondary hydronic system
  • Low ΔT, high system pressure and reverse decoupler flow
  • CHW distribution loop for new lab load


  • Detailed implementation plan to maintain production
  • Convert to full variable flow
  • Modulating evap valves for different chiller DPs
  • Condenser pump and cooling tower VFDs
  • V-ball valves on AHUs to improve distribution flow
  • Install PLC-based Control Engine Optimization® system
  • Integrate with campus Honeywell EBI system

Results That Exceed Client Expectations

Financial Savings

  • $115,000 utility rebate
  • $150,000 annual energy savings
  • 2-year project payback before rebate

Energy Impact

  • 1,250,000 kWh saved annually
  • .36 kW/ton efficiency improvement

Operational Benefits

  • Fully automated system
  • Increased cooling reliability
  • Minimized manual intervention
  • Lower system pressure and new AHU valves eliminated reverse flow
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