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An introduction to EECO2 - Energy Efficiency Consultancy Limited

GMP critical HVAC energy cost reduction in the
pharmaceu...
Who are EECO2
Combined 100+ years experience of Design, Build & Operation
of Hi-tech, Life Sciences & Industrial Facilitie...
What do EECO2 offer?
1.

Single source of Global HVAC energy saving solutions.

2.

Ability to benefit from 12 years of ex...
EECO2 Support Global Pharma Clients In Best Practice HVAC Energy
Reduction
Step 1: Product
Quality Needs

• Temperature
• ...
The Usual Suspects – typically, opportunities are found in….
Facility Type

Opportunity

Potential Reduction

All

Lower a...
Air Change Rate / Set-Back
Flow Rate is directly proportional to rotational
speed of fan motor.
If Flow Rate is halved, th...
Current HVAC parameters across the industry
Company

Grade A

Grade B

Grade C

Grade D

CNC (OSD)

A

0.5 m/s

30 acph

2...
Common barriers to reducing energy / cost?
Lack of available site resource and expertise

QA issues - won’t agree to chang...
The HVAC Energy Intervention Rapid Improvement Workshop (RIW)
The HVAC Energy Intervention Rapid
Improvement Workshop IS:
...
Differences between Standard Energy Audit & HVAC Energy Intervention RIW Approach
Standard Energy Audit

HVAC Intervention...
Global Energy Reduction – Case Studies

EECO2 has provided multinational support in over 20 countries over the last 8 year...
Case Study - Pharma Tablet Manufacturing Suite (South Africa)
Unique Challenges:
• High volumes of fresh air requiring deh...
Pharma Effervescent Product Manufacturing Plant (Argentina)
Project Challenge:
• Very high energy demand driven by the ori...
Energy Management Programme – R&D Campus (UK)

reduction

17%
(+2%)
reduction

30%
(+13%)
reduction

32%
(+2%)
reduction

...
Case Study - Wilton Centre Business & Science Park (UK-Laboratory)
Existing System:
• T Block Older style Face & Bypass cu...
Summary
 HVAC is one of the most significant energy users in pharmaceutical & bio-pharmaceutical
manufacturing.
 A risk ...
Contact Details

For further information, contact:

Keith Beattie

Head of Life Science Division
Energy Efficiency Consult...
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EECO2 GMP critical HVAC energy cost reduction

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EECO2 GMP critical HVAC energy cost reduction

  1. 1. An introduction to EECO2 - Energy Efficiency Consultancy Limited GMP critical HVAC energy cost reduction in the pharmaceutical & life science industry Keith Beattie CEng MIET Chartered Energy Manager MEI EECO2 - Head of Life Science Division 2014
  2. 2. Who are EECO2 Combined 100+ years experience of Design, Build & Operation of Hi-tech, Life Sciences & Industrial Facilities 8 years providing global energy efficiency project implementation and support Sharing industry best practice solutions Empowering & supporting sites to deliver locally Capital avoidance approach – making best use of existing assets Safely driving innovation within industries where product quality is critical 70+ energy workshops delivered & supported globally Clients we have worked with include: AstraZeneca, Camfil, DSM, Eli Lilly, GSK, Ipsen, MedImmune, NHS, Novartis, Pfizer, Sanofi, • benchmarking & modelling • capital project sustainability design reviews • energy engineering standards • energy project development & site support • project management & turnkey delivery • pre & post project energy monitoring • laboratory energy reduction •
  3. 3. What do EECO2 offer? 1. Single source of Global HVAC energy saving solutions. 2. Ability to benefit from 12 years of experience, delivering Energy savings to critical HVAC Systems. 3. Process from initial opportunity identification: • Initial review of HVAC systems to identify potential opportunities = determine viability; • Develop concept designs, scope & impact assessments; • High level review of opportunities with key stakeholders e.g. QA, Production, EHS, Lab Owners, Maintenance Engineering etc; • Risk based approach to define scope & potential savings; • Develop projects to CapEx with costs/benefits/payback etc; • Safety/compliance risk assessments and mitigation plan; • Detailed design, support implementation, commissioning; • Support development & completion of Regulatory documentation; • Verify savings delivered; • On going energy monitoring (continuous commissioning) support to sustain improvements.
  4. 4. EECO2 Support Global Pharma Clients In Best Practice HVAC Energy Reduction Step 1: Product Quality Needs • Temperature • Humidity • Area Classification • Pressure Regimes Step 2: People Comfort/Safety Needs Our unique selling point: Deep technical expertise in pharmaceutical HVAC regulated environments combined with a thorough understanding of QA and regulatory documentation requirements (Risk Based Approach) • Temperature • Humidity • Containment Step 3: Deliver Business Needs with minimum energy • Model site performance • Identify potential savings • Quantify & Scope Deliverable Savings • Agree ECC / Validation approach • Deliver savings • Monitor performance to prove savings
  5. 5. The Usual Suspects – typically, opportunities are found in…. Facility Type Opportunity Potential Reduction All Lower air change rates; fresh air reduction 30-45% Laboratories Reduce fume cupboard capture face velocity; introduce system diversity; convert CAV to VAV 20-30% All Night/Weekend Setback 15-25% Offices/non-GMP areas Night/Weekend shutdown of non-GMP areas 12-18% All Chilled water temperature management and control upgrade 13-15% All Remove redundant plant no longer required due to product changes – redundant safe change units, multi HEPA filtration layers, dehumidifiers, heating & cooling, etc 10-15% Manufacturing/Packaging Reduction of manufacturing spatial requirements i.e. enclose temperature/humidity vulnerable product to reduce conditioned space volumes 10-15% All Improvement in BMS control strategy & set points control 8-12% Manufacturing/Packaging Improvement in dehumidifier heat recuperation 7-12% All Installation of high efficiency filtration – AHU, safe change & HEPA 5-7% Warehouses Air destratification; ventilation improvements; control linked to temperature mapping; eliminate fresh air 5-7%
  6. 6. Air Change Rate / Set-Back Flow Rate is directly proportional to rotational speed of fan motor. If Flow Rate is halved, then Power is reduced by factor of 8; and Pressure is reduced by factor of 4. Air change rate reduction & set-back out of hours is a powerful way to reduce energy consumption, BUT it must only be implemented with a good understanding of area cleanliness / classification supported by robust data. EECO2 can support sites to achieve substantial reductions in ACPH and maintain product quality requirements.
  7. 7. Current HVAC parameters across the industry Company Grade A Grade B Grade C Grade D CNC (OSD) A 0.5 m/s 30 acph 20 acph 15 acph 12-20 acph B 0.5 m/s 45 acph 25 acph 15 acph 15 acph C 0.5 m/s 60 acph 40 acph 25 acph 15-20 acph D 0.5 m/s More than 20 acph More than 20 acph More than 10 acph More than 10 acph E 0.45 m/s 40 acph min 20 acph min 20 acph min F 0.45 m/s 40 acph 25 acph 15 acph 15-20 acph  Large variation in parameters between different companies and even between different sites of the same company.  These parameters are often based of historical norms, with limited/no data to back it up  EECO2 cleanroom trials demonstrate room classifications can be achieved at much reduced air change rate with no detrimental effect on quality
  8. 8. Common barriers to reducing energy / cost? Lack of available site resource and expertise QA issues - won’t agree to change Lack of confidence in savings/cost predictions – can not prove benefits Difficulties in finding the right expertise No resources available Can’t get the downtime / plant availability Too busy dealing with other issues – its not a priority EECO2 provide a unique approach to solving most of the issues above = HVAC Energy Intervention Rapid Improvement Workshop
  9. 9. The HVAC Energy Intervention Rapid Improvement Workshop (RIW) The HVAC Energy Intervention Rapid Improvement Workshop IS: The HVAC Energy Intervention Rapid Improvement Workshop IS NOT: Highly collaborative: • Close team working with site Engineering • Involving all stakeholders – QA, Production, EHS, SLT • A Compliance Audit! Challenging to existing practices: • Air change rates • Pressure regimes • Temperature and Humidity • Set back strategies • Filter strategy – selection and maintenance • Attempting to identify every possible opportunity Focussed on real product quality needs Going to deliver a 100+ page report that is never read
  10. 10. Differences between Standard Energy Audit & HVAC Energy Intervention RIW Approach Standard Energy Audit HVAC Intervention/Rapid Improvement Workshop Experts evaluate site based on their prior experience & sector knowledge vs Team based approach engages internal & external experts to determine what actions are right for the site Identified opportunities are determined by consultant experience and sector knowledge vs Generates large amount of low/no cost actions & opportunity investigations Identifies opportunities at time of audit vs Draws in local site knowledge to take account of historical problems Consultant retains knowledge vs Learning opportunity for site teams Report based vs Action focussed Site sponsor has to “sell” findings & next steps to other stakeholders vs Buy in to findings & next steps is inherent to intervention process – stakeholders are involved in decisions Audit findings often have to be integrated into existing site plans vs Output is one site plan that captures all opportunities We are focussed on getting to action and demonstrating real results for clients in a safe, quality compliant way.
  11. 11. Global Energy Reduction – Case Studies EECO2 has provided multinational support in over 20 countries over the last 8 years
  12. 12. Case Study - Pharma Tablet Manufacturing Suite (South Africa) Unique Challenges: • High volumes of fresh air requiring dehumidification in very challenging ambient conditions • Adapting HVAC system to meet current manufacturing requirements • Reducing dust extraction system volume – installing VSD • Initiating non-operational setbacks • No impact on product quality or manufacturing output EECO2 Solution: • Install fresh air pre-treatment to eliminate dehumidification in AHU • Rebalance area dust extraction system • Install VSD to maintain dust extraction carrier velocity • Reduce fresh air volume & rebalance air change rates to reflect area change of use • Initiate non-operational air volume reduction • Optimise Building Management System (BMS) • Provide all necessary documentation, support validation and change control Client Testimonial: “Its going to be a tough year for all this year and to know that we have such a good team supporting some of these changes makes the job a lot easier” Manufacturing Support Manager Projected Energy Cost Increase
  13. 13. Pharma Effervescent Product Manufacturing Plant (Argentina) Project Challenge: • Very high energy demand driven by the original HVAC design • Unable to meet product critical relative humidity conditions during summer Objective: • Reduce site energy demand without compromising product quality EECO2 Actions: • Reduce air change rates and fresh air volumes • Install VSD to supply fans • Improve air distribution with new diffusers • Upgrade of filtration and maintenance replacement of control valves • Re-commission & balance the complete manufacturing HVAC systems • Completed product risk assessments, Engineering Change Control documentation and all required Regulatory documents. Client Result: ◦ Energy saving delivered: 1,500 MWh per year (£58,000 GBP equivalent) ◦ Simple payback: 11 months Client Testimonial: “The savings delivered during phase 1 has exceeded our expectations and the quality team have supported the risk based approach used to delivery the savings. We now have to move on to phase 2 upgrade which is much more demanding but the confidence and structure knowledge we gained during phase 1 will help us deliver our target for 2011.” Site Director
  14. 14. Energy Management Programme – R&D Campus (UK) reduction 17% (+2%) reduction 30% (+13%) reduction 32% (+2%) reduction 2012 15% 2011 Strategy Development with potential for further 20-25% 2010 Data Validation 2009 aM&T Implementation 32% Energy reduction over 6 years 2008 Opportunity survey 2007 Initial 2006  Implementation of energy management strategy aligned to ISO50001 EMS;  Supported with data analysis and scoped/developed energy & water reduction projects;  Performed Lab fume cupboard trials to demonstrate containment at lower face capture velocities.
  15. 15. Case Study - Wilton Centre Business & Science Park (UK-Laboratory) Existing System: • T Block Older style Face & Bypass cupboards. Over 100 • Individual booster fans serving upto 3 Cupboards (50No) • Header system with 2 large run & standby fans • 4 Large 100% FA systems EECO2 Actions: • 50 % diversity Engineered into the systems • Remove individual booster fans • Retrofit VAV valves & controls to every FC within ceilings • Carried out while labs in use with 1 weeks downtime per lab • FC controller fitted to every cupboard • Pressure control to every lab • Supply VSD & static pressure control fitted • Extract header Bleed damper & static pressure control • Weekend Commissioning to reduce disruption. Client Result: • Over 50% reduction in HVAC energy consumption, saving £205,000 GBP per year • Typical simple payback under 2 years
  16. 16. Summary  HVAC is one of the most significant energy users in pharmaceutical & bio-pharmaceutical manufacturing.  A risk based approach founded on sound data can be used to challenge established company norms. Large savings can be achieved at getting back to company standards.  Technically, the reduction solutions exist and are well proven. Barriers to improvement are often related more to people engagement – soft skills are important.  The collaborative approach of the HVAC energy intervention rapid improvement workshop engages all stakeholders and facilitates the site teams identifying the right solutions for their sites.  Simple payback of HVAC energy reduction projects is almost always under 3 yrs and often 2 yrs or less.
  17. 17. Contact Details For further information, contact: Keith Beattie Head of Life Science Division Energy Efficiency Consultancy Ltd email: info@eeco2.co.uk tel: +44 1625 660717 www.eeco2.co.uk

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