Enhancing competitiveness and achieving sustainability

Enhancing Competitiveness and Achieving Sustainability
Identifying and implementing Energy Efficiency in Pharmaceutical Critical HVAC Systems

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.

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, EPC’s.
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

Current EECO2 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

A History lesson:
To our knowledge there has never been any scientifically based work to identify Pharma Manufacturing ACPH requirements
Current ACPH “Guidelines” are based upon experiments to identify the high failure rates of rocket gyroscopes in the 1950’s 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!

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 now paying 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

The Other Inconvenient Truth!

Sustainable Energy Improvement Process
(SEIP) Using OE Principles

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

HVAC Opportunity
Secondary Manufacturing
– Typically 50-70% of site energy usage is associated with HVAC

Measure

Energy Consumption– Identify Usage!

Energy Map – Identify Usage!
HVAC demand 61% of site total – typically 60 > 70% of facility load can be HVAC

HVAC By kWh

Heating & Cooling Degree Day Graphs

Existing Energy Calculation Model

Analyse

Production (units) v Energy
14% Variable Load
86% Fixed Load

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

Moisture Content vs Electrical Energy
Monthly Energy kWh
Moisture Content g/Kg

CSUM Heating
Improvement Projects? BMS Set point work
Improving Performance
Reducing Performance
Steady State
Improvement Projects? Block 1 HVAC

HVAC - The “Usual suspects”
Top 10 most commonly found opportunities:
High air change rates.
High fresh air volumes.
Challenge area classifications & manufacturing demand.
Operational changes made in areas served.
High energy, low capacity filtration.
BMS not Optimised.
Dehumidifiers not Optimised.
Few VSD’s & where fitted left on “manual”
Switch off/reduce HVAC during none operational hours
Laboratory fume cupboards - upgrades

Identify “size of the prize”

Sample – Energy Audit Summary

Improve

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

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
VSD’s 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

Big Win Opportunities!
Minimise fresh air volumes to achieve pressure cascades, overcome loss & personnel requirements
Fresh air volume has a significant impact on HVAC Energy demand
Season dependant it requires: cooling, heating, filtering, dehumidifying etc
If it requires dehumidification: reactivation heating, cooling & filtration
The Dehumidification process uses significant energy
Minimise air change rates (ACPH) to meet air quality requirements & Production equipment heat loads
Excessive ACPH increases fan power & cooling demand for no benefit
Most areas have excessive ACPH
Review potential to set back ACPH during none operation hours
Identify actual HVAC operational hours vs Manufacturing schedules

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 Area’s 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)

Project Development Process:
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

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 replacement with 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 ΔP & review carrier air velocity

Re - Measure

Low Cost MM&T
Ability to measure, monitor & trend energy usage is critical
EECO2 has developed a range of Mobile Energy Monitoring Units “ MEMU’s”

Renewable Energy Solutions
Combined Heating & Power ( Absorption Cooling)
Wind Turbines
Solar Hot Water
Solar PV
Biofuels
Tidal Schemes
Anaerobic Digestions
Green Energy
Rainwater Recovery

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!

QUESTIONS?
Peter Harrison
Thanks for attending from Camfil & EECO2
Please send any questions by email & we will respond shortly

Enhancing competitiveness and achieving sustainability

by Simply Marcomms on Mar 28, 2011

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Enhancing competitiveness and achieving sustainability — Presentation Transcript