1. Genzyme Sustainability Programs 2012
March 19, 2012

2. Genzyme Sustainability Programs 2012
SMRP Pharmaceutical & Biotech SIG
(Special Interest Group)
Interrelationships between Energy,
Asset Care, and Reliability
Steven Driver Ph.D.
Global Energy Demand Manager
March 19, 2012

3. Genzyme Sustainability Programs Presentation Overview
Genzyme History
Energy Program Structure
Program Performance
Sustainable Commissioning (SC) Concept
Retroactive Commissioning
Ongoing Monitoring
Annual Energy Auditing
Energy Modeling
Ongoing and Retroactive Commissioning Research
OCx/RCx Case study 1 – (177k s.f. research building)
OCx/RCx Case study 2 – (290k s.f. office building)
Linking Energy Management to Asset Care and Reliability

4. Genzyme Sustainability Programs History
Genzyme is a biotechnology company based in Cambridge Massachusetts
Specialization in treating rare genetic diseases
Company was founded in 1981 to meet unmet medical needs
10,000 employees globally
Manufacturing sites in US, UK, IRL, BEL, and FR.
Recently acquired by Sanofi (100,000 employees)

5. Supply Demand Greenhouse Gas
Genzyme Sustainability Programs Energy and Sustainability Program Structure
Mission: To partner with sites to procure and use energy at Genzyme in an efficient, cost effective, and environmentally responsible way
Market Intelligence
Strategic Sourcing
Leverage Scale
Supply
(Directed by
Brenda Henderson)
Competitive Pricing
Reduced Energy Cost
Commodity Quality
Reduced Energy
Increased Reliability
Reduced Operating Cost
Demand
(Directed by
Steven Driver)
Eliminate Waste
Benchmark Metrics
Reduce Risk
Measure Carbon
Footprint
Engage Employees
Greenhouse Gas
(Directed by
Jeff Holmes)
Achieve GHG Target
Environmental Leader

6. Genzyme Sustainability Programs Environmental Target
Received 2012 EPA Climate Leaders award for effective green house gas management and reducing carbon emissions last week in Ft. Lauderdale Florida

7. Genzyme Sustainability Programs Energy Program Results
Saved 3130 MTCO2 from
Saved 6072 MTCO2 from 2009 to present due to sustainable commissioning practices and Implementation of 79 energy conservation projects
Achieved with the program last year a 278% internal rate of return with a 3 ½ month payback on investment resulting in a 5 yr NPV of $9.1M on a 1.4m investment
New mission statement

8. Genzyme Sustainability Programs How did we do it?
Formed a focused team in 2007 (Supply, Demand, GHG)
Conducted ASHRAE level 1 energy audits all major energy consuming sites
Obtained 1.9m in financing to implement ECM’s with a 1 year or less return on investment
Aggressively pursued and completed 79 energy projects
Combined energy auditing, modeling, retroactive and ongoing commissioning into one service

9. Genzyme Sustainability Programs How did we do it?
Allocated funding to sites for ECM engineering, controls, reprogramming, and addressing functional issues
Held weekly teleconferences with our sites to review progress, schedule, budget, and M&V of ECM’s
Measured savings through actual energy usage, conservative engineering calculations, and metering
Aggressively pursued utility rebates

10. Genzyme Sustainability Programs International common theme ECM’s
Lighting levels too high
Lack of lighting sensors
Sequence of operations not optimized for energy
Air change rates beyond EU classification requirements
Humidity and temperature control parameters (not required)
Unnecessary HVAC in mechanical spaces
Broken/out of calibration controls
Free cooling not being utilized
Strategic Demand Control
Thermostatic dead band ranges too narrow
Simultaneous heating and cooling
High purity water and steam usages (steam trap failure)
Lacking use of grey water
Mechanical equipment upgrades
Less than ideal boiler efficiencies
High air filtration requirements

11. Sustainable Commissioning Concept Combining energy auditing, RCx, OCx
Annual energy auditing
(conduct operational interviews, functional testing, energy modeling)
Continuous commissioning SM (OCx)
(artificial intelligence is used to collect fault data)
Retroactive commissioning (RCx)
(collect generate fault data from observations)

12. Sustainable Commissioning Concept Annual functional and operational auditing
The energy assessment team consists of 4 board certified energy professionals trained in energy auditing and energy management with a focus on retroactive commissioning.
Energy Audit Director:
Steven Driver, Ph.D, CEA, CEM
Certified Energy Auditor, Certified Energy Manager
Multi-Discipline Energy Auditor:
Jennifer Jones, CEA
Certified Energy Auditor
Mechanical Energy Auditor:
Jeffery Fong CEA, CEM
Electrical Energy Auditor:
Tim Rossini CEA, CEM, LEED AP

13. Sustainable Commissioning Concept Annual functional and operational auditing
Obtain utility bills, square footage, usage, hours, location, staff to assist in audit, contact info, develop schedule
Kick off meeting, walk-through, functional testing (RCx), operational interviews, exit presentation
Survey, measure, input building into Equest and validate to energy bills
Create final report, estimate costs for ECM’s, savings, and ROI, IRR, NPV – use energy model
Present finding to site management in form of ppt presentation
Return to site to rank ECMS (ROI, quick, simple, feasible
Add high priority ECM’s to international tracking matrix, conduct weekly meetings
Return to site for re-assessment (functional test annually RCx). Implement OCx whenever feasible.

14. Sustainable Commissioning Concept Functional and operational auditing
In-field instrumentation used:
Infrared thermograph
Amp Probes
Lighting level analysis
Vane Annometer
Combustion analysis
Magnehelic gages
Vaneannometer
Infrared thermograph
Magnehelic Gauge
Combustion Analysis
Light Meter
Amp Probe

15. Sustainable Commissioning Concept Functional and operational auditing
Build an energy model and calibrate to existing energy bills to analyze demand and understand where energy is being consumed. Identified ECM’s are profiled and parametric runs completed using different alternatives to understand financial impact on energy

16. Sustainable Commissioning Concept Combining energy auditing, RCx, OCx

17. Sustainable Commissioning Concept Combining energy auditing, RCx, OCx
The process must become sustainable
(Annual Energy Auditing) + (Retroactive Commissioning) +
(Ongoing Monitoring) + (Energy Modeling)
When is it time for a tune up?

18. Sustainable Commissioning Concept Combining energy auditing, RCx, OCx
In 2007 there were still many unanswered questions around commissioning:
In a recent study of 60 commercial buildings conducted by the Oregon Office of Energy, half suffered from control problems such as malfunctioning equipment.
According to Torcellini and Pless (2006), the most frequently cited barrier to widespread use of building commissioning is the decision-makers' uncertainty about its cost-effectiveness.
Gordon (2007) claimed that using computer technology for energy monitoring allows maintenance workers to be called only when something requires repair.
Lee et al. (2007) claimed in a recent study of 60 commercial buildings that over 50% had control problems, 40% had problems with HVAC equipment, and 33% had sensors that were not operating correctly.

19. Sustainable Commissioning Concept Two year study of RCx and Ongoing Monitoring
A study was needed to understand the benefits of commissioning.
From fault detection rates were analyzed in 80 buildings across the US (40 Ocx, 40 Rcx) 100k s.f. in size, mixed use (lab, office, retail, university).
The result was a 58% increase in fault detection for ongoing monitoring and 26% increase for RCx if the two technologies are combined.

20. Sustainable Commissioning Concept 32 common faults were universal throughout the 80 buildings
17 Water / Steam leaks
18 Pneumatic pressure (valve / damper)
19 Fan / Valve Signal Oscillation / Unstable
20 Meter calibration
21 Sensor / Switch / Signal calibration / Low voltage
22 Sensor / switch fault / Controller Flat line
23 Smoke / Hood / Air filter Alarms
24 Envelope leaks / Building Pressurization
25 Visual Observations (incorrect installation,
damage, drainage, missing equipment)
26 Equipment Accessibility Issues / Housekeeping
27 Equipment Performance / VFD
Control/Status/Fault
28 Runtime / Overridden in hand position
29 Engineering issue (over/undersized)
30 Incorrect labeling / Documentation Conflict
31 Sequence Optimization / Tuning / Programming
32 Field/BMS Issue (reversed or incorrect wiring)
1 Discharge / Return temperature fault
Discharge / Exhaust pressure / static flow
Economizer / Outdoor Exhaust Damper
Fault
4 Simultaneous heating and cooling
5 Return / Space Air change rate under / over
6 Space temperature fault
7 Fan Cycling / Damper Oscillation
8 Air balancing / Leaking
9 Visual Thermostat in wrong location
10 Visual Deflection / Vibration / Overheating/Binding
11 Relative Humidification Fault
12 Visual improper valve / damper position
13 Pump / Valve / Oscillation Cycling / Leak bye
14 Water / Steam temperature
15 Water / Steam Pressure
16 Water / Steam flow

21. Sustainable Commissioning Concept Energy savings from ongoing and retroactive commissioning

22. Sustainable Commissioning Concept Combining ongoing monitoring and RCx concurrently (Case Study 1)
In 2011, RCx and RCx were employed concurrently in a LEED rated gold building approximately 6 years old. Energy opportunities identified with corresponding fault number from previous slide:
Economizer malfunction (3)
Scheduling of return fans (31)
Discharge air temperature (1)
VAV box turn-down ratios (27)
CO2 sensor calibration (21)
CW Valve leak bye (13)
Simultaneous heating and cooling (4)
Space temperature faults (6)
Humidification (11)
Occupancy Schedules (31)

23. Sustainable Commissioning Concept Combining ongoing monitoring and RCx concurrently (Case Study 1)
Financial results:

24. Sustainable Commissioning Concept Combining ongoing monitoring and RCx concurrently (Case Study 1)
49 Science Center - additional issue identified through functional energy audit:
Clogged reheat coil: Fan deadheads at 4.25 hp while normal operation is 3.5 hp.
Energy Charge
Demand Charge
HPsaved :
0.750
kW:
0.560
Utility Rate ($/kW*yr):
0.126
Demand Utility Rate($/kW*mo):
19.720
Operating Hrs.:
Operating months.:
12.000
Operating Savings ($/yr):
Demand Savings ($/yr):
For SF-7 & SF-8:
Total $/yr. saved:
This is why we need to audit annually for energy.

25. Sustainable Commissioning Concept Ongoing monitoring (Case Study 2)
Identified 23 opportunities at Genzyme Center, Cambridge (LEED Platinum)
$403,957 savings identified since OCx began in 2009, $259,137 implemented
CO2 savings implemented: 803 Metric Tons

26. Sustainable Commissioning Concept Ongoing monitoring (Case Study 2)
One ECM was to widen thermostat dead bands for occupied times. There was no reported adverse impact to employee comfort and the result was $100,237 per year, 407 tons carbon!

27. Sustainable Commissioning Concept Ongoing monitoring (Case Study 2)

28. Sustainable Commissioning Concept Ongoing Monitoring

29. Genzyme Sustainability Programs Linking energy management to asset care and reliability
GHG Emissions
Reduction
Increased
Reliability
Reduced Energy
Consumption

30. Genzyme Sustainability Programs Linking energy management to asset care and reliability
- Ongoing monitoring identifies abnormalities in equipment operations
Benefits:
- Avoids costly downtime
- Avoids deviations
- Avoid product loss
Increases reliability for critical support systems
Saves money

31. Genzyme Sustainability Programs Linking energy management to asset care and reliability
Why reliability?
Theoretical Max
Breakdowns
Containing and Controlling Loss
Moves the bar
Lost Time
Set-up
Availability
Idle/Minor stop
Lost Speed
Reduced Rate
Efficiency
Performance
Scrap/ Rework
Lost Units
Start up Loss
Current Capacity
Quality
Everything we do must move the line

32. Genzyme Sustainability Programs Linking energy management to asset care and reliability
Changes in Vibration P- F interval 1-9 months
Point where failure starts to occur
Wear Debris in oil P-F interval 1-6 months
Quantitative PM P-F Interval 5-8 weeks
IR Thermograph P-F interval weeks P1 P2
Audible noise P-F interval 1-4 weeks P3 P4
P = Potential Failure P5 P6 F
F = Failure 32

33. - Abnormal valve operation and excessive wear
Genzyme Sustainability Programs Linking energy management to asset care and reliability
Critical manufacturing air handler simultaneous H&C fault
- Abnormal valve operation and excessive wear
- Threat to operations (potential recordable deviation and loss of productivity in space and product)
- 55k in energy being lost

34. Genzyme Sustainability Programs Linking energy management to asset care and reliability
Critical manufacturing air handler simultaneous H&C fault -
Industry
Benchmarking
Energy
Auditing
Modeling
Asset
Care
Reliability
Monitoring
Retroactive
Commissioning
Ongoing
Cost
Quality

35. Genzyme Sustainability Programs Linking energy management to asset care and reliability
We know that:
Excessive energy use/inefficiency is a sign of improper operation,
wear, poor engineering, or an installation problem
Operational issues lead to premature failure
Failures can cause interruptions in manufacturing operations
Manufacturing issues can have legal implications and create loss of revenue

36. Genzyme Sustainability Programs Linking energy management to asset care and reliability
Why take an integrated approach to energy, asset care and reliability?
Gain efficiency through articulation of common program attributes
Ensure continuous improvement of all our programs
Deliver highest level of value to our sites
Drive improved reliability
Reduce energy costs
Increase life expectancy of our assets
Reduce impact on our environment

37. Genzyme Sustainability Programs Linking energy management to asset care and reliability
How?
Enter into an enterprise solution which assists in maintaining efficiency and performance of all assets critical assets
Compliance with International Standards
ISO Compliance – Asset Life Cycle (2014)
ISO Compliance – Energy
ISO Compliance – Environmental

38. Solution: Select an enterprise solution which can:
Genzyme Sustainability Programs Linking energy management to asset care and reliability
Solution: Select an enterprise solution which can:
Optimize maintenance, operational, financial resources
Integrate existing systems (EMS/BMS/EAM/SCADA)
Maintenance based on asset condition rather than arbitrary dates
Optimize reliability and continual improvement through asset intelligence
Integrate asset energy consumption and environmental impact into an EAM strategy
Assist in risk mitigation in the regulatory environment

39. Genzyme Sustainability Programs Linking energy management to asset care and reliability
Software solutions on the market:

40. Genzyme Sustainability Programs Linking energy management to asset care and reliability
When properly metered, an enterprise solution can assist in the analysis of electrical energy usage allowing a better understanding of where peak demand conditions exist

41. Genzyme Sustainability Programs Linking energy management to asset care and reliability
With climate change, we don’t have all the pieces to the puzzle, however, we can lessen the effects on our environment by making smarter choices in how we operate our buildings and train employees.

42. Genzyme Sustainability Programs Conclusion
Through research and practice, we have learned that combining ongoing monitoring, retroactive commissioning, and energy auditing we will obtain:
- lower operating costs and carbon emissions
- continuous reliability and risk mitigation
- less than a 1 year ROI on most ECM's
- increased awareness to the condition of assets
- identification of new financial opportunities