Presentation on theme: "Genzyme Sustainability Programs 2012"— Presentation transcript:
1Genzyme Sustainability Programs 2012 March 19, 2012
2Genzyme Sustainability Programs 2012 SMRP Pharmaceutical & Biotech SIG(Special Interest Group)Interrelationships between Energy,Asset Care, and ReliabilitySteven Driver Ph.D.Global Energy Demand ManagerMarch 19, 2012
3Genzyme Sustainability Programs Presentation Overview Genzyme HistoryEnergy Program StructureProgram PerformanceSustainable Commissioning (SC) ConceptRetroactive CommissioningOngoing MonitoringAnnual Energy AuditingEnergy ModelingOngoing and Retroactive Commissioning ResearchOCx/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
4Genzyme Sustainability Programs History Genzyme is a biotechnology company based in Cambridge MassachusettsSpecialization in treating rare genetic diseasesCompany was founded in 1981 to meet unmet medical needs10,000 employees globallyManufacturing sites in US, UK, IRL, BEL, and FR.Recently acquired by Sanofi (100,000 employees)
5Supply Demand Greenhouse Gas Genzyme Sustainability Programs Energy and Sustainability Program StructureMission: To partner with sites to procure and use energy at Genzyme in an efficient, cost effective, and environmentally responsible wayMarket IntelligenceStrategic SourcingLeverage ScaleSupply(Directed byBrenda Henderson)Competitive PricingReduced Energy CostCommodity QualityReduced EnergyIncreased ReliabilityReduced Operating CostDemand(Directed bySteven Driver)Eliminate WasteBenchmark MetricsReduce RiskMeasure CarbonFootprintEngage EmployeesGreenhouse Gas(Directed byJeff Holmes)Achieve GHG TargetEnvironmental Leader
6Genzyme 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
7Genzyme Sustainability Programs Energy Program Results Saved 3130 MTCO2 fromSaved 6072 MTCO2 from 2009 to present due to sustainable commissioning practices and Implementation of 79 energy conservation projectsAchieved 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 investmentNew mission statement
8Genzyme 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 sitesObtained 1.9m in financing to implement ECM’s with a 1 year or less return on investmentAggressively pursued and completed 79 energy projectsCombined energy auditing, modeling, retroactive and ongoing commissioning into one service
9Genzyme Sustainability Programs How did we do it? Allocated funding to sites for ECM engineering, controls, reprogramming, and addressing functional issuesHeld weekly teleconferences with our sites to review progress, schedule, budget, and M&V of ECM’sMeasured savings through actual energy usage, conservative engineering calculations, and meteringAggressively pursued utility rebates
10Genzyme Sustainability Programs International common theme ECM’s Lighting levels too highLack of lighting sensorsSequence of operations not optimized for energyAir change rates beyond EU classification requirementsHumidity and temperature control parameters (not required)Unnecessary HVAC in mechanical spacesBroken/out of calibration controlsFree cooling not being utilizedStrategic Demand ControlThermostatic dead band ranges too narrowSimultaneous heating and coolingHigh purity water and steam usages (steam trap failure)Lacking use of grey waterMechanical equipment upgradesLess than ideal boiler efficienciesHigh air filtration requirements
11Sustainable 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)
12Sustainable 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, CEMCertified Energy Auditor, Certified Energy ManagerMulti-Discipline Energy Auditor:Jennifer Jones, CEACertified Energy AuditorMechanical Energy Auditor:Jeffery Fong CEA, CEMElectrical Energy Auditor:Tim Rossini CEA, CEM, LEED AP
13Sustainable Commissioning Concept Annual functional and operational auditing Obtain utility bills, square footage, usage, hours, location, staff to assist in audit, contact info, develop scheduleKick off meeting, walk-through, functional testing (RCx), operational interviews, exit presentationSurvey, measure, input building into Equest and validate to energy billsCreate final report, estimate costs for ECM’s, savings, and ROI, IRR, NPV – use energy modelPresent finding to site management in form of ppt presentationReturn to site to rank ECMS (ROI, quick, simple, feasibleAdd high priority ECM’s to international tracking matrix, conduct weekly meetingsReturn to site for re-assessment (functional test annually RCx). Implement OCx whenever feasible.
15Sustainable 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
16Sustainable Commissioning Concept Combining energy auditing, RCx, OCx
17Sustainable 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?
18Sustainable 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.
19Sustainable 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.
20Sustainable Commissioning Concept 32 common faults were universal throughout the 80 buildings 17 Water / Steam leaks18 Pneumatic pressure (valve / damper)19 Fan / Valve Signal Oscillation / Unstable20 Meter calibration21 Sensor / Switch / Signal calibration / Low voltage22 Sensor / switch fault / Controller Flat line23 Smoke / Hood / Air filter Alarms24 Envelope leaks / Building Pressurization25 Visual Observations (incorrect installation,damage, drainage, missing equipment)26 Equipment Accessibility Issues / Housekeeping27 Equipment Performance / VFDControl/Status/Fault28 Runtime / Overridden in hand position29 Engineering issue (over/undersized)30 Incorrect labeling / Documentation Conflict31 Sequence Optimization / Tuning / Programming32 Field/BMS Issue (reversed or incorrect wiring)1 Discharge / Return temperature faultDischarge / Exhaust pressure / static flowEconomizer / Outdoor Exhaust DamperFault4 Simultaneous heating and cooling5 Return / Space Air change rate under / over6 Space temperature fault7 Fan Cycling / Damper Oscillation8 Air balancing / Leaking9 Visual Thermostat in wrong location10 Visual Deflection / Vibration / Overheating/Binding11 Relative Humidification Fault12 Visual improper valve / damper position13 Pump / Valve / Oscillation Cycling / Leak bye14 Water / Steam temperature15 Water / Steam Pressure16 Water / Steam flow
21Sustainable Commissioning Concept Energy savings from ongoing and retroactive commissioning
22Sustainable 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)
23Sustainable Commissioning Concept Combining ongoing monitoring and RCx concurrently (Case Study 1) Financial results:
24Sustainable 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 ChargeDemand ChargeHPsaved :0.750kW:0.560Utility Rate ($/kW*yr):0.126Demand Utility Rate($/kW*mo):19.720Operating Hrs.:Operating months.:12.000Operating Savings ($/yr):Demand Savings ($/yr):For SF-7 & SF-8:Total $/yr. saved:This is why we need to audit annually for energy.
25Sustainable 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 implementedCO2 savings implemented: 803 Metric Tons
26Sustainable 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!
27Sustainable Commissioning Concept Ongoing monitoring (Case Study 2)
29Genzyme Sustainability Programs Linking energy management to asset care and reliability GHG EmissionsReductionIncreasedReliabilityReduced EnergyConsumption
30Genzyme Sustainability Programs Linking energy management to asset care and reliability - Ongoing monitoring identifies abnormalities in equipment operationsBenefits:- Avoids costly downtime- Avoids deviations- Avoid product lossIncreases reliability for critical support systemsSaves money
31Genzyme Sustainability Programs Linking energy management to asset care and reliability Why reliability?Theoretical MaxBreakdownsContaining and Controlling LossMoves the barLost TimeSet-upAvailabilityIdle/Minor stopLost SpeedReduced RateEfficiencyPerformanceScrap/ ReworkLost UnitsStart up LossCurrent CapacityQualityEverything we do must move the line
32Genzyme Sustainability Programs Linking energy management to asset care and reliability Changes in Vibration P- F interval 1-9 monthsPoint where failure starts to occurWear Debris in oil P-F interval 1-6 monthsQuantitative PM P-F Interval 5-8 weeksIR Thermograph P-F interval weeksP1P2Audible noise P-F interval 1-4 weeksP3P4P = Potential FailureP5P6FF = Failure32
33- Abnormal valve operation and excessive wear Genzyme Sustainability Programs Linking energy management to asset care and reliabilityCritical 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
34Genzyme Sustainability Programs Linking energy management to asset care and reliability Critical manufacturing air handler simultaneous H&C fault-IndustryBenchmarkingEnergyAuditingModelingAssetCareReliabilityMonitoringRetroactiveCommissioningOngoingCostQuality
35Genzyme 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 problemOperational issues lead to premature failureFailures can cause interruptions in manufacturing operationsManufacturing issues can have legal implications and create loss of revenue
36Genzyme 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 attributesEnsure continuous improvement of all our programsDeliver highest level of value to our sitesDrive improved reliabilityReduce energy costsIncrease life expectancy of our assetsReduce impact on our environment
37Genzyme 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 assetsCompliance with International StandardsISO Compliance – Asset Life Cycle (2014)ISO Compliance – EnergyISO Compliance – Environmental
38Solution: Select an enterprise solution which can: Genzyme Sustainability Programs Linking energy management to asset care and reliabilitySolution: Select an enterprise solution which can:Optimize maintenance, operational, financial resourcesIntegrate existing systems (EMS/BMS/EAM/SCADA)Maintenance based on asset condition rather than arbitrary datesOptimize reliability and continual improvement through asset intelligenceIntegrate asset energy consumption and environmental impact into an EAM strategyAssist in risk mitigation in the regulatory environment
39Genzyme Sustainability Programs Linking energy management to asset care and reliability Software solutions on the market:
40Genzyme 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
41Genzyme 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.
42Genzyme 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