Low-Cost Tweaks Yield Big-Time Savings
Once Jack Dale Associates (JDA) quantified mechanical-system interactions for Texaco’s data center, specified techniques were employed to upgrade the plant while avoiding disruptions to data-processing operations. Total construction costs for chiller-plant renovations commissioned by JDA were less than $600,000.
Procedures outlined by the engineering team improved energy efficiency and continue to save the petrochemical company more than $100,000 per year in utility costs. The design not only solved operating problems, but also improved the facility’s ability to increase its chilled-water reserve for future expansions. Best of all, the upgrades reduced energy consumption. Key features include:
The upgrades help set system demand and to ensure that only the required amount of chilled water is distributed.
Before JDA began work on the project, Texaco had received a number of proposals for resolving the facility’s system problems. The least onerous of the proposals would have required a two-week shutdown of the entire 5,000-ton chiller plant and over $2 million to complete.
Table 1 – Existing HVAC System Parameters
Table 2 – Savings from Mechanical Plant Re-engineering
|Chiller loads:||2,200||1,760||Chiller loads:||1,600||1,280|
|Total HP & kW:||3,172||2,371||Total HP & kW:||1,832||1,398|
|Dead head factor:||0.90||Pump kW saved:||973|
|Total kW Demand:||2,134 kW||Total kW demand:||1,398|
|Use factor:||0.80||Use factor:||0.80|
|Annual pump utility cost:||$235,462||Annual pump utility cost:||$45,530|
|Added utility cost for new office space:||$79,684|
|Net annual utility savings after chiller plant renovations:||$110,248|
Average cost per kWh: 0.055 $/kWh