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Real Results from Critical Facilities' Projects

Clorox Chilled Water Optimization Project

Chilled Water System Optimization for Reduced Energy Consumption

Process Cooling

Global Facility Solutions (GFS) partnered with The Clorox Company to optimize the chilled water system at their 350,000 sq ft Maryland manufacturing plant in Aberdeen, MD, leveraging the BGE Smart Energy Savers Custom Program to achieve significant energy savings and utility incentives.

Challenge

Project Objectives

Perform operational analysis of two 337-ton Trane centrifugal chillers operating 24/7 for 5+ days per week
Reduce baseline and annual energy consumption for chillers producing 30°F chilled water for process equipment
Leverage utility incentives and achieve significant energy savings
Optimize process chilled water system for 24/7 operation at 4,160 volts

Analysis and Solution

Scope of Work

Conduct comprehensive review of energy consumption baseline for two process-related chillers
Develop and implement energy-saving measures across 5 major system components
Provide full MEP design and permit-level drawings for installation
Perform energy modeling for savings verification
Coordinate with BGE incentive team to secure maximum rebate

Solutions

Comprehensive chilled water system optimization, including:

Installation of a 190-ton part-load chiller to improve process chilled water system efficiency
Introduction of Variable Frequency Drives (VFDs) on 4 chilled water pumps and 3 cooling tower fans
Replacement of two aging 100 HP water pumps with high-efficiency models
Upgrade of ATC controls to manage new equipment and optimize system performance
Full MEP design and permit-level drawings for installation of all new equipment
Energy modeling for savings verification, projecting 15% overall system efficiency improvement

The Clorox Chilled Water Optimization Project, designed and implemented by GFS, delivered substantial energy savings and secured a significant utility incentive, demonstrating the effectiveness of strategic system upgrades in industrial settings. This project showcases GFS’s expertise in leveraging utility programs and implementing tailored solutions for energy-intensive manufacturing processes, resulting in a projected annual utility cost savings of over $80,000.

The audit provided ownership and property staff with valuable insights to inform targeted decision-making toward investment planning and achieving energy reduction goals.

Results

Results By the Numbers

$231,806 incentive awarded through the BGE Smart Energy Savers Custom Program ($0.28/kWh saved)
Anticipated annual energy savings of approximately 827,900 kWh/year
10% to 20% reduction in baseline energy consumption
Energy savings between 25 kW to 35 kW and 160,000 kWh to 220,000 kWh annually
190 Ton supplemental water-cooled chiller added to increase system efficiency
Project payback period of less than 3 years