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Enhancing competitiveness and achieving sustainability

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Identifying and implementing Energy Efficiency in Pharmaceutical Critical HVAC Systems …

Identifying and implementing Energy Efficiency in Pharmaceutical Critical HVAC Systems

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  • 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 & 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 & customer expectations.Huge CO2 benefits can be achieved.
  • Transcript

    • 1. Enhancing Competitiveness and Achieving Sustainability
      Identifying and implementing Energy Efficiency in Pharmaceutical Critical HVAC Systems
    • 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, 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
    • 4. 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
    • 5. 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!
    • 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 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
    • 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.
      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
    • 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
      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
    • 28. 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
      • 29. Season dependant it requires: cooling, heating, filtering, dehumidifying etc
      • 30. If it requires dehumidification: reactivation heating, cooling & filtration
      • 31. 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
      • 32. Most areas have excessive ACPH
      • 33. Review potential to set back ACPH during none operation hours
      Identify 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 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)
    • 35. 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
    • 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 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
    • 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 “ MEMU’s”
    • 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