Merck CHW Plant 45 – West Point, PA


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Chiller Plant Optimization

Background

Merck West Point is a pharmaceutical manufacturing site located in Pennsylvania. This plant is one of multiple plants on site totaling over 80,000 Tons.

6,250 Ton CHW Plant

  • (2) 1,250 Ton Trane CVHF Chillers
  • (3) 1,250 Ton Trane CVHE Chillers
  • (5) CW Pumps
  • (5) CHW Pumps
  • (10) Cooling tower cells

Project Scope

The scope included installation of VFDs on the five condenser water pumps and five chilled water pumps as well as a comprehensive control logic modification to improve plant efficiency.

Optimization Sequences:

  • Optimal equipment staging
    • Towers, Pumps, Chillers
  • Optimal CWST and CW Flow
  • CHW DP reset
  • CW and CHW bypass control

Services

  • Controls Sequence
  • Hydraulic Modeling
  • P&ID Drawings of Existing System
  • Investment Grade Audit
    • Evaluation of multiple options
  • Rebate Filing/Management
  • M&V

Optimization Stats

First 3 months of operation

  • Avg Total Plant kW reduction: 43%
  • Total kWh Reduction: 451,640 kWh
  • Avg CWP Reduction in kW: 76%
  • Avg CHWP Reduction in kW: 73%
  • Avg Tower Reduction in kW: 42%

Value Added

Energy Rebate:

  • PA ACT 129
  • $150,000

Energy Savings:

  • Over $218,000 per year

Project Simple Payback:

  • 2.06 Years

Annual Energy Reduction:

  • Over 3,300,000 kWh