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2. Camfil Farr Training Academy Webinar Programme 2011
Attend a Free Camfil Farr Webinar from the comfort of your own
office
Every Friday at 11am GMT
Register at www.lowenergyairfilter.co.uk
This webinar programme is aimed at assisting you with your business
processes demonstrating how substantial energy saving opportunities
can be made. Each Webinar lasts no more than 30-45 minutes and is
free of charge.
3. Who is EECO2?
EECO2 Energy Efficiency HVAC Consultants ltd- based in Macclesfield
Cheshire
Pharma HVAC Energy Consultancy services
Legislative energy solutions AC Inspections, Part L compliance,
EPCs.
Global Pharmaceutical HVAC Energy solutions
Identify opportunities & supporting implementation
Combined 60+ years experience of Design & Building Pharma
Facilities
9+ years delivering innovative Energy focused Pharma HVAC
solutions
Sharing Industry best practice solutions
4. CurrentEECO2 Activity
Sustainable Energy Improvement Programmes: Global Pharmaceutical
manufacture:
Delivering HVAC energy solutions across 79 sites in 33
Countries
Supporting Global SEIP events
Client selected Energy Alliance Partners :
Camfil:
Schneider Electric:
Munters:
QA supported risk based approach, pilots & implementation
Integrating viable solutions & savings into a single
implementation strategy
Best practice & knowledge sharing
5. A History lesson:
To our knowledge there has never been any scientifically based work
to identify Pharma Manufacturing ACPH requirements
CurrentACPH Guidelines are based upon experiments to identify the
high failure rates of rocket gyroscopes in the 1950s for the
USAF
Similarly for Aseptic manufacturing laminar air velocities have not
been fully challenged.
Compliance requirements are based upon air quality
Collaborative scientifically based review of ACPH & Laminarity
has just been completed
The initial indications are prepare for change!
6. An Inconvenient Truth!
Compliance driven, business risk aversion, has resulted in over
designed systems for many years
HVAC systems commonly found to be 50% + oversized
This has now come back to haunt us,as we are nowpaying higher
energy costs and increased emissions
Key Challenge; maintaining compliance and product quality, at the
same time as reducing energy costs
Otherwise how do you retain your competitive edge, in a global
market, if your fixed overhead is constantly increasing?
The recession may temporarily slow Energy cost increases, providing
a breathing space to mitigate your baseline Energy costs
Corporate Responsibility Sustainability. ISO16001
7. The Other Inconvenient Truth!
8. Sustainable Energy Improvement Process
(SEIP) Using OE Principles
9. Define
OE Principles (Define, Measure, Analyse, Improve)
Understand where your energy is being used
Prioritise CO2, kWh,
Identify the Opportunities (size of the prize!)
Prioritise focus low risk quick win to Capital intensive
Identify cost to implement
ROI with savings
Identify potential impact
Programme implementation
Verify savings
10. HVAC Opportunity
Secondary Manufacturing
Typically 50-70% of site energy usage is associated with HVAC
11. Measure
12. Energy Consumption Identify Usage!
13. Energy Map Identify Usage!
HVAC demand 61% of site total typically 60 > 70% of facility
load can be HVAC
14. HVAC By kWh
15. Heating & Cooling Degree Day Graphs
16. Existing Energy Calculation Model
17. Analyse
18. Production (units) v Energy
14% Variable Load
86% Fixed Load
19. Gas vs Heating Degree Days
Variable load External condition Driven
Scatter could represent poor control or inaccurate meter
reading.
BaseLoad Independent of Degree Days ie
24/7 fan operation. Humidification / Dehum, Re-Heat
Hot Water, Process Water, WFI
20. Moisture Content vs Electrical Energy
Monthly Energy kWh
Moisture Content g/Kg
21. CSUM Heating
Improvement Projects? BMS Set point work
Improving Performance
Reducing Performance
Steady State
Improvement Projects? Block 1 HVAC
22. HVAC - The Usual suspects
Top 10 most commonly found opportunities:
High air change rates.
High fresh air volumes.
Challengearea classifications & manufacturing demand.
Operational changes made in areas served.
High energy, low capacity filtration.
BMS not Optimised.
Dehumidifiers not Optimised.
Few VSDs & where fitted left on manual
Switch off/reduce HVAC during none operational hours
Laboratory fume cupboards -upgrades
23. Identify size of the prize
24. Sample Energy Audit Summary
25. Improve
26. Energy Design Flow Path
Production Area:
Product & Compliance
need driven
Design HVAC to
Meet - not exceed
production
requirements
Chillers &
Support Utilities
1.Identify current product need
2. Review; Classification & Pressure Regimes etc.
3. Energy Audit space
4. Calculate required ACPH
5. Design HVAC Plant to meet 1>4
6. Ensure all elements of design are Energy Efficient
7. System should be fit for purpose
8. Designed to support 1>7
9. Using Energy Efficiency;
Best Engineering Practice
10. Integrate relevant innovation
Minimising Air Change Rates is the key issue
27. Quick Win Opportunities?:
Design review of HVAC systems ACPH & Fresh air volumes
Review potential to switch off or set back air volumes in non cGMP
areas at nights & week ends
Secondary Packaging
Offices
Warehouse
Modify fresh air HVAC systems to recirculation system with free
cooling where viable mitigate potential cross contamination issues
- filtration
BMS Optimisation, strategy review,system maintenance
VSDs with volume control reduces Energy demand & improves
flexibility
Review current AHU & terminal filtration, replace with low
energy types
Challenge requirement for dehumidification & energy upgrade
when required
28. Big Win Opportunities!
Minimise fresh air volumes to achieve pressure cascades, overcome
loss & personnel requirements
29. Season dependant it requires: cooling, heating, filtering,
dehumidifying etc 30. If it requires dehumidification: reactivation
heating, cooling & filtration 31. The Dehumidificationprocess
uses significant energy Minimise air change rates (ACPH) to meet
air quality requirements & Production equipment heat
loads
32. Most areas have excessive ACPH 33. Review potential to set
back ACPH during none operation hoursIdentify actual HVAC
operational hours vs Manufacturing schedules
34. Key Project Issues;
Energy Efficiency need not compromise :Compliance, product quality,
quantity or safety
Structured approach to identifying and safely delivering Energy
Efficiency
Functional Requirement Specification (FRS): area classifications,
product & production requirements, identifies cGMP & change
control requirements
Identify viable solutions to reduce HVAC energy
Review the Production Areas current and projected HVAC demand
Balance that demand with the most Energy Efficient HVAC
operation
Plan production impact minimisation
Energy upgrading can qualify for Enhanced Capital Allowances
(EHA)
35. Project DevelopmentProcess:
Following completion of HVAC Energy Audit:
Step 1: Prioritise upgrades based on: best cost savings @ least
business risk
Step 2: Commence with quick win opportunities
Step 3: Complete FRS risk assessment with: Eng/QA/Users/EHS
Step 4: Devise low impact implementation strategy
Step 5: Programme to minimise and manage shutdowns & business
impact
Step 6: Verify savings projected have been delivered
36. Energy Focused Strategic Planning:
Development of Business Risk Strategic Planning:
Virgin Refrigerant R22 ceased in January 2010, usage banned in 2015
affects older chillers
Phased Chiller replacementwith energy efficient replacements based
in LCCA
Chiller replacement design load based on reduced cooling demand not
historical
Recommission HVAC air systems to ensure they meet cGMP Guides
Install EEF1 motors on failure or VSD installation
Phased upgrade to low energy filtration
Dust extract units: air pulse on P & review carrier air
velocity
37. Re - Measure
38. Low Cost MM&T
Ability to measure, monitor & trend energy usage is
critical
EECO2 has developed a range of Mobile Energy Monitoring Units
MEMUs
39. Renewable Energy Solutions
Combined Heating & Power ( Absorption Cooling)
Wind Turbines
Solar Hot Water
Solar PV
Biofuels
Tidal Schemes
Anaerobic Digestions
Green Energy
Rainwater Recovery
40. Way Forward
Think that you have already picked your low hanging fruit think
again!
Take ownership of energy management
Identify where your energy is used
If you cannot measure it you cannot manage it!
Team work solutions Engineering/QA/Production/EHS
Do not be afraid to challenge/challenge/challenge perceived
standards
The bottom line is!
If you do not make it cheaper someone else will!
41. QUESTIONS?
Peter Harrison
Thanks for attending from Camfil & EECO2
Please send any questions by email & we will respond
shortly