Enhancing Campus Sustainability: Real-Time Flow Monitoring for Cooling System Optimization

Growing Demand on Cooling Systems

Over time, as the campus expanded, the demand for cooling grew, and so did the strain on the HVAC systems. Primary chillers were being overworked, especially in large buildings like their multi-purpose arena, which seats 12,400 people. The system was experiencing "low Delta T," a condition where the temperature difference between the chilled water supply and return was smaller than optimal. This inefficient operation led to excessive energy consumption, unnecessary wear on equipment, and reduced system capacity in other areas of the campus.

To address these issues, the university sought a solution to optimize flow rates, improve energy efficiency, and reduce operating costs.

Advanced Solution

To improve system efficiency, the university turned to Badger Meter and implemented a cutting-edge solution from the BlueEdge™ portfolio. The Dynasonics^® TFX-5000 Ultrasonic Clamp-On Flow Meter was chosen for its ability to provide real-time flow and energy data across the chilled water network, allowing facility managers to gain insight into system performance instantly. To monitor steam energy usage on the heating side, the university also deployed the Vortex^® VN2000 Hot Tap Insertion Flow Meter, safeguarding that both sides of the HVAC system were optimized for efficiency.

These state-of-the-art flow meters were integrated with the university’s existing building management system (BMS), providing real-time data on flow and energy usage. This enabled facility managers to quickly identify any inefficiencies, such as suboptimal flow rates or excessive energy consumption, and take corrective action promptly.

The non-intrusive design of the TFX-5000 allowed for quick installation without modifying existing infrastructure, while the hot tap insertion design of the VN2000 made it easy to deploy in high-pressure applications. Together, these solutions provided a comprehensive monitoring system that provided both immediate and long-term improvements to the campus’s energy management.

Results & Impact

By implementing the TFX-5000 and VN2000 flow meters, the university was able to:

• Increase System Efficiency: Real-time monitoring helped identify low Delta T conditions, allowing the university to adjust flow rates and optimize the operation of chillers. This improved system staging, reduced unnecessary chiller runtime and minimized over-pumping.
• Lower Operating Costs: With more efficient flow management, the university saved over $20,000 per month in electricity costs by reducing energy consumption and avoiding overwork of the primary chillers.
• Enhance Sustainability: The improved efficiency not only reduced energy and water consumption but also lowered CO₂ emissions, contributing to the university’s sustainability efforts and environmental goals.

Through the use of an advanced flow monitoring solution, the university has successfully optimized its cooling system, achieving significant cost savings while maintaining the comfort of students and faculty across the campus.