1. Energy Management at Jealott’s Hill
Owen Everall
Site Engineering and Facilities Manager
17th July 2014
Classification: Internal Use Only
Classification: PUBLIC
2. 2
Introduction
Classification: PUBLIC
• Jealott’s Hill Site
• Jealott’s Hill Infrastructure Legacy
• Maintenance Strategy
• Energy Management
• Energy Metrics (Consumption and Cost)
• Electricity Management
• Gas Management
• Case Study on B100 Boiler System
• Associated Benefits
• Summary
• Close
4. 4
The White House – the first laboratory built in by ICI in 1928
Classification: PUBLIC
5. 5
…the site has grown since then…
…the site was established in 1927
and there has been a farm here for
centuries
Classification: PUBLIC
6. 6
Jealott’s Hill today
Jealott’s Hill site is 60 acres
with a buildings footprint 65,000 m²
comprising offices, labs, glasshouses,
restaurant, gym, IT server building…
An international employee base of
850 staff involved in a range of science
activities related to world agriculture
Classification: PUBLIC
We have the largest
glasshouse research
complex in Europe at
4,000m2
9. 9
Jealott’s Hill Infrastructure Legacy
…too expensive to operate…
• Johnson Controls commissioned R&D Building Maintenance Benchmark Data
• Jealott’s Hill operating at 2½ times the cost of majority of our peers
Classification: PUBLIC
10. 10
Jealott’s Hill Infrastructure Legacy
…too expensive to operate…
…out of control…
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
kVA
• Frequently throughout the summer of 2004 the site limit of 5MVA was being breached
• Led to a project being initiated to reinforce the capacity to 7.5MVA at a cost of £500k
Classification: PUBLIC
5MVA electrical
capacity being breached
11. 11
Jealott’s Hill Infrastructure Legacy
…too expensive to operate…
…out of control…
…over capitalised…
• Many cases where too much plant has been installed resulting in high maintenance cost
and poor efficiencies
Classification: PUBLIC
13. 13
Maintenance Strategy
Safe People
• minimise maintenance routines (e.g. direct drives),
• reduce operational parameters (i.e. temperatures, pressures),
• eliminate plant
Simple Process(es)
• waste
• site operating procedures
• out of hours call outs
• control loops
Sustainable Plant
• maximise value add at project stage (capital investment)
• maximise service delivery opportunity (ability to control)
• minimise intervention post installation (maintenance)
• minimise impact on environment
Classification: PUBLIC
Sustainabl
e
Simpl
e
Safe
14. 14
Maintenance Strategy
Safe People
• minimise maintenance routines (e.g. direct drives)
• reduce operational parameters (i.e. temperatures, pressures)
• eliminate plant
Simple Process(es)
• Waste
• Out of Hours Call Outs
• Building Services Control
Sustainable Plant
• maximise value add at project stage (capital investment)
• maximise service delivery opportunity (ability to control)
• minimise intervention post installation (maintenance)
• minimise impact on environment
Classification: PUBLIC
Sustainabl
e
Simpl
e
Safe
15. 15
Waste Management in 2004
• No recycling
• 38 waste streams identified
• Using 12 waste contractors
• Only 8% of site waste processed
• £1000 per week in maintenance
• £1000 per week in fuel
• 3 tonnes of fuel/tonne of waste burnt
Classification: PUBLIC
Sustainabl
e
Simpl
e
Safe
16. 16
Waste Management
● 2006
- Ceased on site incineration
- Total Waste Management Contract
- Recycling rate approximately 15%
Glasshouse soil recycling June 2009
Classification: PUBLIC
Sustainabl
e
Simpl
e
Safe
17. 17
Out of Hours Call Outs
0
200
400
600
800
1000
1200
2004 2013
Classification: PUBLIC
Sustainabl
e
Simpl
e
Safe
18. 18
Out of Hours Call Outs
0
200
400
600
800
1000
1200
2004 2013
90% reduction
Classification: PUBLIC
Sustainabl
e
Simpl
e
Safe
22. 22
Maintenance Strategy
Safe People
• minimise maintenance routines (e.g. direct drives),
• reduce operational parameters (i.e. temperatures, pressures),
• eliminate plant
Simple Process(es)
• Waste
• Out of Hours Call Outs
• Building Services Control
Sustainable Plant
• minimise maintenance requirement (simple, safe, reliable)
• minimise impact on environment (efficient)
• maximise opportunity at project stage (specify what you want)
Classification: PUBLIC
Sustainabl
e
Simpl
e
Safe
23. 23
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
Classification: PUBLIC
24. 24
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
Classification: PUBLIC
25. 25
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
£-
£500,000
£1,000,000
£1,500,000
£2,000,000
£2,500,000
£3,000,000
Gas Electricity
2004
£440k
£1,250k
Classification: PUBLIC
26. 26
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
£-
£500,000
£1,000,000
£1,500,000
£2,000,000
£2,500,000
£3,000,000
Gas Electricity
2004
2013
£560k
£1,820k
Classification: PUBLIC
27. 27
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
£-
£500,000
£1,000,000
£1,500,000
£2,000,000
£2,500,000
£3,000,000
Gas Electricity
2004
2013
2013
£1,210k
£2,920k
Classification: PUBLIC
30. 30
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
Classification: PUBLIC
31. 31
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
Classification: PUBLIC
33. 33
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
Classification: PUBLIC
34. 34
Demand led Control Strategies rather than time enabled
Time
Time Enabled Control
Supply
Classification: PUBLIC
35. 35
Demand led Control Strategies rather than time enabled
Time
Time Enabled Control
Supply
Classification: PUBLIC
36. 36
Demand led Control Strategies rather than time enabled
Time
Oversupply
Time Enabled Control
Supply
Classification: PUBLIC
37. 37
Demand led Control Strategies rather than time enabled
Time
Oversupply
Time Enabled Control
Time
Demand Enabled Control
Supply
Classification: PUBLIC
38. 38
Demand led Control Strategies rather than time enabled
Time
Oversupply
Time Enabled Control
Time
Demand Enabled Control
Supply
Classification: PUBLIC
39. 39
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux, BMS)
Classification: PUBLIC
40. 40
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux, BMS)
- Rationalise plant (air compressors, intermediate pumps,...)
Classification: PUBLIC
45. 45
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux)
- Rationalise plant (air compressors, intermediate pumps,...)
- LED Lighting
Classification: PUBLIC
46. 46
LED Lighting in corridor, office, breakout and laboratory spaces
Classification: PUBLIC
47. 47
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux)
- Rationalise plant (air compressors, intermediate pumps,...)
- LED Lighting
- Integrating plant onto the BMS
Classification: PUBLIC
48. 48
B170 Central Research Dispensary
Stable 24/7 operation
Providing an environment for 900,000 compounds
Classification: PUBLIC
49. 49
B170 Central Research Dispensary Cooling
• Two sources of cooling;
• Chilled water controlled by BMS
Classification: PUBLIC
51. 51
B170 Central Research Dispensary Cooling
• Two sources of cooling;
• Chilled water controlled by BMS
• 8 DX split systems stand alone, on 24/7 under own control
Classification: PUBLIC
53. 53
B170 Central Research Dispensary Cooling
• Chilled water controlled by BMS
• 8 DX split systems stand alone, full 24/7 under own control
• Integrated the two cooling systems to work in harmony
under the control of the BMS
• Improved control of plant to prevent heating and cooling
systems from fighting each other
Classification: PUBLIC
56. 56
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux)
- Rationalise plant (air compressors, intermediate pumps,...)
- LED Lighting
- Integrating plant onto the BMS
- Preventing heating and cooling plant from fighting each other in
Controlled Environment Rooms
Classification: PUBLIC
62. 62
Site Boilerhouses by Consumption (kWhrs)
Confidential: Internal use only
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
B100 B23 B110 B167 B101 B170 B88 B161 B173
2004
32MW installed capacity
Classification: PUBLIC
63. 63
Site Boilerhouses by Consumption (kWhrs)
Confidential: Internal use only
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
B100 B23 B110 B167 B101 B170 B88 B161 B173
2004
2013
16MW installed capacity
Halved the boiler capacity
Classification: PUBLIC
64. 64
Site Boilerhouses by Consumption (kWhrs)
Confidential: Internal use only
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
B100 B23 B110 B167 B101 B170 B88 B161 B173
2004
2013
Case study
Classification: PUBLIC
66. 66
B100 Original Boiler Installation 10MW
Boiler4
Boiler3
Boiler2
Boiler1
• Single circuit
• Constant volume
• BMS enable only
• Temperature control
on return of boilers
• Operating at 120ºC
T
Heating Pump
Classification: PUBLIC
Controlling at 120ºC
120ºC 120ºC 120ºC120ºC
68. 68
Heating Pumps
• Belt driven
• Fixed speed
• Difficult access
• Runs 24/7
• Costs >£30k pa to run
Classification: PUBLIC
69. 69
Heater Battery 3 Port Valve Arrangement
Heater Battery 3 Port Valve
Double Regulating Valve
• All of the boiler water flows all of the time (constant volume system)
Unused water flows through bypass
Classification: PUBLIC
73. 73
Modulating Burner Controls via BMS
• Firing rate set by BMS based on demand from the building
• Reduces the number of times a burner is fired thus improving efficiency
Classification: PUBLIC
74. 74
B100 Secondary Heating Pumps
• Direct drive
• Inverter speed
control
• Variable duty
• Easy access
• Operating at 82°C
• Runs on demand
Classification: PUBLIC
79. 79
Heater Battery 2 Port Valve Arrangement
Heater Battery 2 Port Valve
• Only boiler water that is required is supplied (variable volume system)
No wasted water
Classification: PUBLIC
80. 80
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for
outside air temperature)
Classification: PUBLIC
81. 81
Compensated Boiler Flow Temperature Control
0
5
10
15
20
25
80 80 80 80 80 80 80 81 82 83 84 85 86 87 88 89 90 90 90 90 90
OutsideAirTemperature
Boiler Flow Temperature
Classification: PUBLIC
As outside temperature falls we
increase boiler flow temperature
82. 82
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for
outside air temperature)
● Unoccupied Strategy
- Lab AHU controls ‘night temperature setback’ to provide fabric
protection
Classification: PUBLIC
84. 84
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for
outside air temperature)
● Unoccupied Strategy
- Lab AHU controls ‘night set back temperature’ to provide fabric
protection
- lower fabric set point determined by dew point control
Classification: PUBLIC
85. 85
Dew Point Control for Unoccupied Time Zone
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Lower night setback
temperature
where conditions allow
avoiding dew point
time
Classification: PUBLIC
Additional
energy saving
86. 86
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for
outside air temperature)
● Unoccupied Strategy
- Lab AHU controls ‘night set back temperature’ to provide fabric
protection
- lower fabric set point determined by dew point control
● Occupied Strategy; set point is based on ambient outside temp and is
also influenced by lux level
Classification: PUBLIC
87. 87
Lux Control
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Lower day temperature
when sun shines
time
Classification: PUBLIC
Energy saving
88. 88
B100 Gas Consumption after modifications 51% reduction
Classification: PUBLIC
Energy saving
89. 89
Normalised Gas Consumption (space and temperature)
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
2004 2006 2008 2010 2012 2014
69% reduction
Classification: PUBLIC
93. 93
Summary
• A robust Engineering Maintenance Strategy will deliver
reduced utility consumption as well as…
reduced operational risk (safer)
better building services control (simpler)
reduced operational maintenance costs (sustainable)
Classification: PUBLIC
