Elements of a succesful Energy Management approach for Life Sciences industry
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Sustainable Drug Manufacturing - Start With the Easy Parts The life sciences industry is determined to get greener. To conserve natural resources, reduce carbon footprints and improve their bottom lines, pharmaceutical makers are seeking to improve their resource management and establish sustainable manufacturing platforms. But how do they begin? Pharmaceutical executives are starting with the (relatively) easy parts: corporate energy management (CEM), and the measurement automation that empowers it. Read more »
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Elements of a succesful Energy Management approach for Life Sciences industry
- 2. What is CEM? • ‘CEM’ refers to sets of actions that move accountability for energy outcomes to upper levels of the firm. • With CEM, energy is no longer the sole responsibility of plant managers and engineers. CEM programs are designed to involve many areas of business activity, such as accounting, marketing, and others that were not traditionally concerned with energy. • Bringing corporate‐level attention and management into the picture helps to ensure enterprise‐wide opportunities are explored. From US Dept of Energy: http://www1.eere.energy.gov/industry/bestpractices/corporate_energy.html Definition Of Corporate Energy Management…
- 3. • Allocation of energy cost to produced goods and services is not accurate or useful in understanding the true cost of goods sold • Poor maintenance of equipment and assets causes energy waste • Operators are not aware of the consequences of decisions that create excessive energy usage or demand • Self generated energy is difficult to integrate into the operation • Data for effective energy management is captured in other plant systems not integrated with operations
- 4. The ultimate goals are: • To reduce fuel use • Reduce CO2 emissions • Maximize cumulative avoided energy costs • Accrue recurring annual savings • Improve the overall plant efficiency. The savings realized will depend upon the nature of the initial conditions, but experience shows energy savings in excess of 10% can be reasonably expected.
- 9. Ad Hoc Awareness Managed The “Low Hanging Fruit” is addressed Energy efficient lighting, occupancy sensors, remove lighting Variable speed drives installed Low flow water fixtures installed and re‐use of water for boilers, etc. Spot check and manual reporting of energy/water usage monthly or weekly Reduce ‐ steam pressure / dehumidification / air changes Improve insulation on pipes / boilers, etc. Journey: Starts With Pain & Uncertainty…
- 10. Ad Hoc Awareness Managed The “Low Hanging Fruit” is addressed Energy efficient lighting, occupancy sensors, remove lighting Variable speed drives installed Low flow water fixtures installed and re‐use of water for boilers, etc. Spot check and manual reporting of energy/water usage monthly or weekly Reduce ‐ steam pressure / dehumidification / air changes Improve insulation on pipes / boilers, etc. Challenges Did it work? Is it still working? Which measures undertaken contributed most of the savings? Are there unintended consequences of these measures? What if Roberto leaves? Journey: Starts With Pain & Uncertainty…
- 16. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Journey: Awareness Leads To Management…
- 17. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning Journey: Awareness Leads To Management…
- 18. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning The benefits of the energy management are sustained year after year Journey: Awareness Leads To Management…
- 19. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning The benefits of the energy management are sustained year after year Automation is in place to prevent deviations Journey: Awareness Leads To Management…
- 20. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning The benefits of the energy management are sustained year after year Automation is in place to prevent deviations Smart Grid becomes a competitive advantage, bring it on! Journey: Awareness Leads To Management…
- 21. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning The benefits of the energy management are sustained year after year Automation is in place to prevent deviations Smart Grid becomes a competitive advantage, bring it on! Challenges Journey: Awareness Leads To Management…
- 22. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning The benefits of the energy management are sustained year after year Automation is in place to prevent deviations Smart Grid becomes a competitive advantage, bring it on! Challenges Change Journey: Awareness Leads To Management…
- 23. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning The benefits of the energy management are sustained year after year Automation is in place to prevent deviations Smart Grid becomes a competitive advantage, bring it on! Challenges Change Continuous improvement Journey: Awareness Leads To Management…
- 24. Ad Hoc Awareness Managed Energy Management is an organizational competency Everyone knows how energy usage and deviation effect financial performance Energy is managed as a variable cost and used by ERP for planning The benefits of the energy management are sustained year after year Automation is in place to prevent deviations Smart Grid becomes a competitive advantage, bring it on! Challenges Change Continuous improvement Are there unintended consequences? Journey: Awareness Leads To Management…
- 25. Automatic •Direct to Meters (also wireless) •Meters thru PLC/DCS •RTU from remote sites •Building Management System •Utility Interval Readings Mobile •IntelaTrac •Mobile Data Collection External Context •Weather‐ Current, Forecast •Utility Rates •Demand Response Signals from Grid Internal Context •Operational Events from automation and MES •Asset State from automation •Order, Batch, SKU Energy Usage Data Usage Context Corporate KPI Asset Management CMMS ERP/MES Energy Metrics Work Request Energy Usage InTouch HMI •Real‐time view of energy usage •Configuration of the application Web Portal •Run Pre‐ configured reports Production Worker Local Energy Manager Corporate Energy Manager Energy Information Advanced Analysis and Simulation Rich Data Intelligence •Run Pre‐ configured reports •EMI for Operations Corporate Energy Management Context Transforms Data Into Information…
- 29. • A well structured long term plan for continual improvement • A companywide cultural ownership approach • An awareness of the importance of sustained cost savings
- 30. • A well structured long term plan for continual improvement • A companywide cultural ownership approach • An awareness of the importance of sustained cost savings • Establishment of multi disciplinary teams to implement CEM
- 31. • A well structured long term plan for continual improvement • A companywide cultural ownership approach • An awareness of the importance of sustained cost savings • Establishment of multi disciplinary teams to implement CEM • Integrate these efforts into other corporate improvement programs
- 35. • You need an understanding of where you are now in terms of Energy Management • Establishing a baseline in order to gauge future improvement • If you cannot measure it you cannot prove it. If you cannot prove it, you cannot define the ROI
- 36. • You need an understanding of where you are now in terms of Energy Management • Establishing a baseline in order to gauge future improvement • If you cannot measure it you cannot prove it. If you cannot prove it, you cannot define the ROI • The challenge is to provide the return on investment (ROI) necessary to obtain funding.
- 37. • You need an understanding of where you are now in terms of Energy Management • Establishing a baseline in order to gauge future improvement • If you cannot measure it you cannot prove it. If you cannot prove it, you cannot define the ROI • The challenge is to provide the return on investment (ROI) necessary to obtain funding. • Start slowly but take every opportunity to provide metering capabilities when you make changes
- 38. • You need an understanding of where you are now in terms of Energy Management • Establishing a baseline in order to gauge future improvement • If you cannot measure it you cannot prove it. If you cannot prove it, you cannot define the ROI • The challenge is to provide the return on investment (ROI) necessary to obtain funding. • Start slowly but take every opportunity to provide metering capabilities when you make changes • In this way you will achieve the necessary metering ‘resolution’ to be able to discern the ‘detail’
- 42. • Begin metering and sub‐metering plus ‘virtual’ metering • Monitor electrical energy, water, air, fuel, and steam • Correlate this data to the operational phase, batch, location, date and time.
- 43. • Begin metering and sub‐metering plus ‘virtual’ metering • Monitor electrical energy, water, air, fuel, and steam • Correlate this data to the operational phase, batch, location, date and time. • Produce Key Performance indicators (KPI’s) to report information in context
- 44. • Begin metering and sub‐metering plus ‘virtual’ metering • Monitor electrical energy, water, air, fuel, and steam • Correlate this data to the operational phase, batch, location, date and time. • Produce Key Performance indicators (KPI’s) to report information in context • Utilize industry available software tools to convert this wealth of information in useful data.
- 45. • Begin metering and sub‐metering plus ‘virtual’ metering • Monitor electrical energy, water, air, fuel, and steam • Correlate this data to the operational phase, batch, location, date and time. • Produce Key Performance indicators (KPI’s) to report information in context • Utilize industry available software tools to convert this wealth of information in useful data. •You can then relate usage to time and location and thereby determine the true ‘Energy Intensity’
- 46. • Begin metering and sub‐metering plus ‘virtual’ metering • Monitor electrical energy, water, air, fuel, and steam • Correlate this data to the operational phase, batch, location, date and time. • Produce Key Performance indicators (KPI’s) to report information in context • Utilize industry available software tools to convert this wealth of information in useful data. •You can then relate usage to time and location and thereby determine the true ‘Energy Intensity’ •‘Energy Intensity’ = energy required per unit production, corrected for location and time of usage.