Enhancing Competitiveness and Achieving Sustainability<br />Identifying and implementing Energy Efficiency in Pharmaceutic...
Camfil Farr Training Academy Webinar Programme 2011<br />Attend a Free Camfil Farr Webinar from the comfort of your own of...
Who is EECO2?<br />EECO2 – Energy Efficiency HVAC Consultants ltd  - based in Macclesfield Cheshire<br />Pharma HVAC Energ...
Current  EECO2 Activity<br />Sustainable Energy Improvement Programmes: Global Pharmaceutical manufacture:<br />Delivering...
A History lesson:<br />To our knowledge there has never been any scientifically based work to identify Pharma Manufacturin...
An Inconvenient Truth!<br />Compliance driven, business risk aversion, has resulted in over designed systems for many year...
The Other Inconvenient Truth!<br />
Sustainable Energy Improvement Process<br />(SEIP) Using OE Principles<br />
Define<br />OE Principles (Define, Measure, Analyse, Improve)<br />Understand where your energy is being used<br />Priorit...
HVAC Opportunity<br />Secondary Manufacturing<br /> – Typically 50-70% of site energy usage is associated with HVAC<br />
Measure<br />
Energy Consumption– Identify Usage!<br />
Energy Map – Identify Usage!<br />HVAC demand 61% of site total – typically 60 > 70% of facility load can be HVAC<br />
HVAC By kWh <br />
Heating & Cooling Degree Day Graphs<br />
Existing Energy Calculation Model<br />
Analyse<br />
Production (units) v Energy <br />14% Variable Load<br />86% Fixed Load<br />
Gas vs Heating Degree Days<br />Variable load External condition Driven<br />Scatter could represent poor control or inacc...
Moisture Content vs Electrical Energy<br />Monthly Energy kWh<br />Moisture Content g/Kg<br />
CSUM Heating<br />Improvement Projects? BMS Set point work<br />Improving Performance     <br />Reducing Performance<br />...
HVAC - The “Usual suspects”<br />Top 10 most commonly found opportunities:<br />High air change rates. <br />High fresh ai...
Identify “size of the prize”<br />
Sample – Energy Audit Summary<br />
Improve<br />
 Energy Design Flow Path<br />Production Area: <br />Product & Compliance <br />need driven<br />Design HVAC to <br />Meet...
Quick Win Opportunities?:<br />Design review of HVAC systems – ACPH & Fresh air volumes<br />Review potential to switch of...
Big Win Opportunities!<br />Minimise fresh air volumes to achieve pressure cascades, overcome loss & personnel requirement...
 Season dependant it requires: cooling, heating, filtering, dehumidifying etc
 If it requires dehumidification: reactivation heating, cooling & filtration
 The Dehumidification  process uses significant energy     </li></ul>Minimise air change rates (ACPH) to meet air quality ...
 Most areas have excessive ACPH
 Review potential to set back ACPH during none operation hours</li></ul>Identify actual HVAC operational hours vs Manufact...
Key Project Issues;<br />Energy Efficiency need not compromise :  Compliance, product quality, quantity or safety<br />Str...
Project Development  Process:<br />Following completion of HVAC Energy Audit:<br />Step 1: Prioritise upgrades based on: b...
Energy Focused Strategic Planning:<br />Development of Business Risk Strategic Planning:<br />Virgin Refrigerant R22 cease...
Upcoming SlideShare
Loading in …5
×

Enhancing competitiveness and achieving sustainability

1,048 views

Published on

Identifying and implementing Energy Efficiency in Pharmaceutical Critical HVAC Systems

Published in: Education
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
1,048
On SlideShare
0
From Embeds
0
Number of Embeds
63
Actions
Shares
0
Downloads
10
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide
  • It is estimated that Pharma Manufacturing globally emits 100,000,000 Tonnes of Co2 Annually.
  • Typical modelling of HVAC system to provide energy consumption data for targeting energy savings.
  • Need a structured &amp; managed approach to delivery of energy savingsWas at a site in the Philippines. Engineering started switching plant off at weekend without Quality input. Caused quality issues and now difficulties to implement change.
  • Company needs to decide its requirements for sustainability before embarking on renewable technologies. They all have a place but will specific to the site &amp; customer expectations.Huge CO2 benefits can be achieved.
  • Enhancing competitiveness and achieving sustainability

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

    ×