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.
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
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
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
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
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
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