A practical approach to pharmaceutical HVAC energy reduction

29 Oct 2013

Spirax-Sarco, Cheltenham

Keith Beattie Head of Life Science Division

Energy Efficiency Consultancy Ltd

Agenda

1. Introduction to EECO2

2. HVAC Energy Hogs – The ‘Usual Suspects’

3. Barriers to energy reduction

4. Proven techniques to overcome barriers

5. Case Studies

6. Summary & Discussion

Who are EECO2

Combined 100+ years experience of Design, Build & Operation of Hi-tech, Life Sciences & Industrial Facilities

8 years providing global energy efficiency project implementation and support

Sharing industry best practice solutions

Empowering & supporting sites to deliver locally

Capital avoidance approach

Safely driving innovation within industries where product quality is critical

70+ energy workshops delivered & supported globally

Clients we have worked with include: Pfizer, GSK, Eli Lilly, Novartis, Sanofi, DSM, Ipsen, Camfil, NHS,

• benchmarking & modelling • capital project sustainability design reviews • energy engineering standards • energy project development & site

support • project management & turnkey delivery • pre & post project energy monitoring • laboratory energy reduction •

The Usual Suspects

Facility Type Opportunity Potential Reduction

All Lower air change rates; fresh air reduction 30-45%

Laboratories Reduce fume cupboard capture face velocity; introduce system diversity; convert CAV to

VAV

20-30%

All Night/Weekend Setback 15-25%

Offices/non-GMP areas Night/Weekend shutdown of non-GMP areas 12-18%

All Chilled water temperature management and control upgrade 13-15%

All Remove redundant plant no longer required due to product changes – redundant safe

change units, multi HEPA filtration layers, dehumidifiers, heating & cooling, etc

10-15%

Manufacturing/Packaging Reduction of manufacturing spatial requirements i.e. enclose temperature/humidity

vulnerable product to reduce conditioned space volumes

10-15%

All Improvement in BMS control strategy & set points control 8-12%

Manufacturing/Packaging Improvement in dehumidifier heat recuperation 7-12%

All Installation of high efficiency filtration – AHU, safe change & HEPA 5-7%

Warehouses Air destratification; ventilation improvements; control linked to temperature mapping;

eliminate fresh air

5-7%

Air Change Rate / Set-Back

Flow Rate is directly proportional to rotational speed of fan motor.

If Flow Rate is halved, then Power is reduced by factor of 8;

and Pressure is reduced by factor of 4.

Current HVAC Values vs. Trial Results

Company Grade A Grade B Grade C Grade D CNC (OSD)

A 0.5 m/s 30 acph 20 acph 15 acph 12-20 acph

B 0.5 m/s 45 acph 25 acph 15 acph 15 acph

C 0.5 m/s 60 acph 40 acph 25 acph 15-20 acph

D 0.5 m/s More than 20

acph

More than 20

acph

More than 10

acph

More than 10

acph

E 0.45 m/s 40 acph min 20 acph min 20 acph min

F 0.45 m/s 40 acph 25 acph 15 acph 15-20 acph

Trial Work

Operational

0.25 to 0.35 m/s 10 acph 5 acph 5 acph Less than 5

acph

Trial Work at

Rest

0.15 m/s 10 acph 5 acph ~ 0 acph ~0 acph

What barriers exist to reducing energy / cost?

No finance / budget available

Lack of confidence in savings/cost predictions – can not prove benefits

QA won’t agree to change

Difficulties in finding the right expertise

No resources available

Can’t get the downtime / plant availability

Too busy dealing with other issues – its not a priority

Energy Kaizens / Interventions

Team based, focussed energy/water savings event

Involves/engages all stakeholders

EECO2 facilitate site teams to identify opportunities and to devise solutions – engagement & buy-in

Follows DMAIC process

• standard Operational Excellence tools

• but focussed on sustainability & cost

Typical output:

• JDI’s;

• scoped & costed projects;

• projects for further investigation

EECO2 have delivered over 70 events for several global clients.

Energy Kaizens / Interventions

Findings/Observations:

1. HVAC opportunities identified across all sites: air change reduction; fresh air reduction; BMS optimisation; out-of-hours setback; maintenance opportunities

2. Energy management practices are in their infancy on most sites – with undeveloped metering/analysis, KPI’s, use of energy teams, continuous commissioning & site communications

3. Site teams engage well with the intervention process

4. QA / EHS buy in to projects is critical & process works to deliver this

5. External consultant facilitated, but site team responsible for decisions

Results:

Site Saving Identified

(MWh per yr)

% of Site

energy / cost

No of

Projects

No of

Investigations/

JDI’s

Cost Saving

per year

Project Cost

Estimate

Simple

Payback (ROI)

A 3,606 17% / 20% n/a n/a €221K n/a n/a

B 7,698 12% / 20% 11 107 €620K €1,085K 1.8yrs

C 6,310 11% / 15% 4 78 €573K €1,305K 2.3yrs

D 5,146 6% / 13% 5 220 €319K €670K 2.1yrs

Investment capital cost per MWh saving: €110-206 per MWh reduction

Case Studies Global Pharma Company – R&D Campus Building

Global Pharma Company – Mixed Use Building

Building contains mixture of operations including

Laboratories

Test Facilities

Solid Dose manufacturing

Sterile manufacturing

The use of this building has changed considerably in recent years and a through design & optimisation review

will yield considerable savings.

EECO2 carried out a high level data collection audit to enable a Concept review of energy saving opportunities

within the building. The concepts proposed included:

• Reducing fresh air intake by re-configuring the HVAC system

• Introduction of a variable air volume system for laboratory fume cupboards & reducing air change rates

• Introduction of low energy filters and high efficiency motors

• BMS optimisation review

We have identified opportunities within the Sterile Manufacturing area, but would not recommend making any

changes at this time, one step at a time

Global Pharma Company – “Size of the Prize”

Description kWh £ T. CO2

Air change reduction 1,542,011 124,889 1,420

HVAC Set Back 1,064,285 46,256 134

Fresh Air reduction 3,269,197 128,784 131

BMS Optimization 1,030,960 83,499 950

HEM Motors & VSD's 126,889 10,277 117

High Efficiency Filtration 149,150 12,080 137

Totals 7,182,492 405,785 2,889% of HVAC Totals 42% 40% 46%

Building 510

Based upon 2011 data & January 2013 Energy costs, savings

have been success factored

Air change

reduction

21%

HVAC Set Back

15%

Fresh Air

reduction

46%

BMS

Optimization

14%

HEM Motors &

VSD's

2%

High Efficiency

Filtration

2%

Case Studies The Wilton Centre

The Wilton Centre (ex ICI laboratories)

Existing System

• T Block Older style Face & Bypass cupboards. Over 100

• Individual extract fans serving upto 3 Cupboards (50No)

• Header system with 2 large run & standby fans

• 4 Large 100% FA systems

Delivered

• 50 % diversity Engineered into the systems

• Remove individual extract fans

• Retrofit VAV valves & controls to every FC within ceilings

• Carried out while labs in use with 1 weeks downtime per lab

• FC controller fitted to every cupboard

• Pressure control to every lab

• Supply VSD & static pressure control fitted

• Extract header Bleed damper & static pressure control

• Weekend Commissioning to reduce disruption.

Case Study - Wilton Centre (Ex ICI laboratories - T-Block)

Metered data from Lab Block based on ~100 Fume Cupboards

0

20

40

60

80

100

120

140

160

180

200

Jan

-05

Mar-

05

May-0

5

Jul-

05

Sep

-05

No

v-0

5

Jan

-06

Mar-

06

May-0

6

Jul-

06

Sep

-06

No

v-0

6

Jan

-07

Mar-

07

May-0

7

Jul-

07

Sep

-07

No

v-0

7

Jan

-08

Mar-

08

May-0

8

Jul-

08

Sep

-08

No

v-0

8

Jan

-09

Mar-

09

May-0

9

Jul-

09

Sep

-09

No

v-0

9

Jan

-10

Mar-

10

May-1

0

Jul-

10

Sep

-10

No

v-1

0

Jan

-11

Mar-

11

May-1

1

Jul-

11

Sep

-11

No

v-1

1

T-Block MW.h

T-Block MW.h

Pre Project Metered Energy Use

66% Energy

Reduction

Post Project Metered Energy Use

Summary

HVAC is one of the most significant energy users in pharmaceutical & bio-pharmaceutical manufacturing.

A risk based approach founded on sound data can be used to challenge established company norms. Large savings can be achieved at getting back to company standards.

Technically, the reduction solutions exist and are well proven. Barriers to improvement are often related more to people engagement – soft skills are important.

The collaborative approach of the HVAC intervention engages all stakeholders and facilitates the site teams identifying the right solutions for their sites.

Simple payback of HVAC energy reduction projects is almost always under 3 yrs and often 2 yrs or less.

Questions?

For further information, contact:

Keith Beattie

Head of Life Science Division

Energy Efficiency Consultancy Ltd

email: keith.beattie@eeco2.co.uk mob: 07825 371 432