| erik familial hypercholesterolemia usa genzyme sustainability programs 2012 march 19, 2012
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|www.genzyme.com
Erik Familial Hypercholesterolemia USA
Genzyme Sustainability Programs 2012
March 19, 2012
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
Genzyme Sustainability Programs Presentation Overview
3
• 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
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)
Genzyme Sustainability ProgramsEnergy 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
Demand(Directed by
Steven Driver)
Greenhouse Gas(Directed by Jeff Holmes)
Supply(Directed by
Brenda Henderson)
Market Intelligence
Strategic Sourcing
Leverage Scale
Competitive Pricing Reduced Energy Cost Commodity Quality
Eliminate Waste Benchmark Metrics Reduce Risk
Measure Carbon Footprint Engage Employees
• Achieve GHG Target• Environmental Leader
• Reduced Energy• Increased Reliability • Reduced Operating Cost
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
Genzyme Sustainability Programs Energy Program Results
7
Saved 3130 MTCO2 from 2007-09
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
Genzyme Sustainability ProgramsHow 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
Genzyme Sustainability ProgramsHow 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
Genzyme Sustainability ProgramsInternational common theme ECM’s
• Lighting levels too high
• Lack of lighting sensors
• Sequence of operations not optimized for energy
• Air change rates beyondEU 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
Sustainable Commissioning ConceptCombining 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)
Sustainable Commissioning ConceptAnnual 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, CEACertified Energy Auditor
Mechanical Energy Auditor: Jeffery Fong CEA, CEMCertified Energy Auditor, Certified Energy Manager
Electrical Energy Auditor:Tim Rossini CEA, CEM, LEED AP Certified Energy Auditor, Certified Energy Manager
Sustainable Commissioning ConceptAnnual functional and operational auditing
Request for Information
Conduct Assessment
Build Energy Model
Generate Report
Present Findings
Conduct Workshop
Track Implementation of ECMs
Re-Assess
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.
Sustainable Commissioning ConceptFunctional and operational auditing
• In-field instrumentation used:
− Infrared thermograph
− Amp Probes
− Lighting level analysis
− Vane Annometer
− Combustion analysis
− Magnehelic gages
Vaneannometer
Infrared thermograph
Amp ProbeLight Meter
Magnehelic Gauge
Combustion Analysis
Sustainable Commissioning ConceptFunctional 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
Sustainable Commissioning ConceptCombining energy auditing, RCx, OCx
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?
Sustainable Commissioning ConceptCombining 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.
Sustainable Commissioning ConceptTwo year study of RCx and Ongoing Monitoring
A study was needed to understand the benefits of commissioning.
From 2008-2010 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.
Sustainable Commissioning Concept32 common faults were universal throughout the 80 buildings
1 Discharge / Return temperature fault2 Discharge / Exhaust pressure / static flow3 Economizer / Outdoor Exhaust Damper Fault4 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 position 13 Pump / Valve / Oscillation Cycling / Leak
bye14 Water / Steam temperature 15 Water / Steam Pressure16 Water / Steam flow
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 / VFD Control/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)
Sustainable Commissioning ConceptEnergy savings from ongoing and retroactive commissioning
Sustainable Commissioning ConceptCombining 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)
Sustainable Commissioning ConceptCombining ongoing monitoring and RCx concurrently(Case Study 1)
Financial results:
DescriptionENE Controls Gas Elect TotalOngoing Commissioning $8,744 $69,818 $78,562Retroactive Commissioning $32,000 $45,500 $77,500Rebates Total $156,062
2011 Items Frequency 2011 2012 2013 2014 2015 2016
Antispated Cash Flow half first year 78,031 0 0 0 0 0
Implementation cost one time (50,537) 0 0 0 0 0Net Cash Flows 27,494 156,062 156,062 156,062 156,062 156,062
Cash flows for ECM IRR (50,537) 156,062 156,062 156,062 156,062 156,062Cash flows for program IRR (50,537) 156,062 156,062 156,062 156,062 156,062NPV (at 10.67%) $550,433Payback (months) 3.9IRR of program 309%
USD
SavingsInvested Cost$20,394$60,400$24,000-$54,257$50,537
Financial AnalysisParameters
Sustainable Commissioning ConceptCombining ongoing monitoring and RCx concurrently(Case Study 1)
49 Science Center - additional issue identified through functional energy audit:
Clogged reheat coil: Fan deadheads at 4.25 hp while normal operation is 3.5 hp.
Energy Charge Demand Charge
HPsaved : 0.750 HPsaved : 0.750
kW: 0.560 kW: 0.560
Utility Rate ($/kW*yr): 0.126
Demand Utility Rate($/kW*mo): 19.720
Operating Hrs.: 8760.000Operating months.: 12.000
Operating Savings ($/yr): 617.554
Demand Savings ($/yr): 132.400
For SF-7 & SF-8: 1235.107 For SF-7 & SF-8: 264.800
Total $/yr. saved: 1499.908
This is why we need to audit annually for energy.
Sustainable Commissioning ConceptOngoing 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
Sustainable Commissioning ConceptOngoing 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!
Sustainable Commissioning ConceptOngoing monitoring (Case Study 2)
Sustainable Commissioning ConceptOngoing Monitoring
Genzyme Sustainability Programs Linking energy management to asset care and reliability
GHG Emissions Reduction
IncreasedReliability
Reduced Energy Consumption
Genzyme Sustainability Programs Linking energy management to asset care and reliability
• 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
Genzyme Sustainability Programs Linking energy management to asset care and reliability
Why reliability?
Availability
Efficiency
Performance
Quality
Set-up
Breakdowns
Reduced Rate
Scrap/ Rework
Start up Loss
Idle/Minor stop
Lost
Tim
e
Lost
Spe
ed
Lost
Uni
ts
Theoretical Max
Current Capacity
Containing and Controlling Loss
Moves the bar
Everything we do must move the line
Genzyme Sustainability Programs Linking energy management to asset care and reliability
32
Point where failure starts to occur
Changes in Vibration P-F interval 1-9 months
Wear Debris in oil P-F interval 1-6 months
Audible noise P-F interval 1-4 weeks
P1 P2
P5
P6
F
IR Thermograph P-F interval 3-12 weeks
P3
P = Potential Failure
F = Failure
Quantitative PM P-F Interval 5-8 weeks
P4
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
Genzyme Sustainability Programs Linking energy management to asset care and reliability
Critical manufacturing air handler simultaneous H&C fault
-
Industry Benchmarking
EnergyAuditing
Energy Modeling
AssetCare
Reliability Monitoring
Retroactive Commissioning
OngoingMonitoring
CostReliability
Quality
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
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
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 55000 Compliance – Asset Life Cycle (2014) ISO 50001 Compliance – Energy ISO 14001 Compliance – Environmental
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
Genzyme Sustainability Programs Linking energy management to asset care and reliability
Software solutions on the market:
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
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.
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