2012 latin american hse conference - cambe site_v0
TRANSCRIPT
a Novartis company
Londrina PR – Brazil
2012 Latin American HSE Conference
Cambé’s Site Energy Experience
a Novartis company
Alex de Paula, Gabriel Gimenes, Marcelo Costa
March 19-21, 2012 – São Paulo, Brazil
This initiative is part of SPA Program
2 | CIGE | 2011
Welcome to Cambé SiteStart up 2004
Capacity: 1,4 b bulk units/ 65 m pack units
Total Built Area: 32.165 m2
Total Land Area: 294.155 m2
ComOps
QC, QA, Eng., Supply, HSE, HR
Hormonal Bulk
RegularBulk
HBWLogistic
Packaging
Utilities/ Infra
3 | CIGE | 2011
2011Overall Results and Consumptions
Water
(-2,6%) 32.004 m³
Diesel
(-70%) 55,5 GJ1.500 l
LPG
(+17%) 5.718 GJ
115.750 kg
Electricity
(+2,7%) 23.712 GJ
6.587.319 KWh
Energy: ACT 2011 vs. TGT: - 309 GJ (- 1,1%)Volume Processing (bulk units): ACT 2011 vs. PY 2010: + 24,5%
4 | CIGE | 2011
Performance Management KPIs awareness increase PMP objectives
5 | CIGE | 2011
Performance Management Action Plan through PDCA methodology
6 | CIGE | 2011
• Reduce surge occurrences when external temperatures under 20oC due to high TR capacity of chillers
Key benefits:• Minimize operational and
maintenance issues• Avoid Capex with new lower
capacity chillers
• Room for energy improvement (on evaluation after chillers revamping implemented)
Energy Projects 2011Chillers Logic Implementation
7 | CIGE | 2011
1) Chillers:• Refurbishment of condensers tube• VSD installation (1 chiller)• Revaluation of primary looping to run chillers according to design parameters
Implemented in Dec/11Results: In the past, only one chiller could run during external higher temperatures and humidity (e.g. rainy days). Current situation both chillers are running and energy efficiency under evaluation.
Energy Projects 2011Chillers Refurbishment and Lighting Efficiency
2) Lighting:
24000 h33200250 WNAV-250WFuture
HQI-T400W
Type Power Lúmen Vida útil
Existing 400 W 35000 12000 h
2.1) External areas:
Implemented in October 2011.
24000 h17000150 WNAV-150W
HQI-T250W
Power Lúmen Vida útil
250 W 20000 12000 h
2.2) Internal areas:
Partially implemented in 2011.Due date June 2012
metallic
sodium
Future
Type
Existing metallic
sodium
8 | CIGE | 2011
Energy Projects 2011On-line Electricity Monitoring• Implemented on-line electricity
monitoring in order to be compliant with “Corporate HSE Guideline 14: Energy Standards for Buildings and Equipment”
• Understand electricity consumption profile and react accordingly.
• System under commissioning
First results:• Estimations are useful!• ...but might generate
misleading information when detailed analysis must be performed.
Rough estimations prior to system implemented
9 | CIGE | 2011
Energy Challenging 2011Wastewater Treatment Plant
CAR Amount:USD 1,87mTreatment flow design: 3.525 m³/month
Applicable requirements from GL14 identified and to be reviewed on basic design: monitoring energy consumption, lighting system and efficiency of motors.
Natural light in the new building
10 | CIGE | 2011
1) (Implemented) Scheduling of sanitization of 2 water storages tank after full utilization (twice a year): ~ 121 m³
2) (SOP under discussion with HSE) Scheduling of sanitization of 1 dedicated water storage tank after firefighter staff training (once a year): ~ 144 m³
3) (Implemented) Water storage volume of toilets reduced from 12 l to 6 l: ~ 600 m³
4) (Implemented) Limit water flow in 120 taps: ~ 900 m³
Water Projects 2011
11 | CIGE | 2011
Awareness 2011“Turn off the lights” campaign
Turn off the lights when leaving the room!Save Energy: Sandoz and the Planet thank you
12 | CIGE | 2011
Awareness 2011Communication
13 | CIGE | 2011
Cambé Energy TGT 2012
Volume Processing (bulk units) :
TGT 12 vs. PY 2011: + 12,5%
14 | CIGE | 2011
1) Air Compressors replacement with 2 new compressors with VSD, oil-free design and reduced lower power capacity Investment: on evaluation Potential savings: on evaluation
Business Case Due date: May/12Responsible: Wagner (Utilities) and Eder (Projects)
Energy Projects 2012
2) Replacement of motors to fullfill the Corporate HSE Guidance Note 14.2 Technical Specifications on Buildings and Equipment Investment: on evaluation Potential savings: on evaluation
Due date: August/2012Responsible: Alex (Utilities)
15 | CIGE | 2011
Corrective Action: Steam leakage correction
Energy Projects 2012On-line LPG consumption monitoring• Implement on-line LPG consumption within electricity monitoring system in order to increase
data accuracy and reduce response time (reaction time)
16 | CIGE | 2011
2) Christ PW system: Water Recovery from RO
Water Projects 2012
3) On-line Water consumption monitoring in order to increase data accuracy and reduce response time (reaction time)
1) Blowndown efficiency increase of cooling water system: implementation of NALCO 3D TRASAR technology in order to introduce real-time monitoring, actives based control technology, stress resistant chemistry and 24/7 information management capabilities to detect, determine and deliver improved scale, corrosion and microbiological performance.
Investment: noPotential savings: system implemented, trend on evaluationDue date: Mar/12 Responsible: Wagner (Utilities)
Due date: business case Apr/12 Responsible: João and Wagner (Utilities)
Investment: on evaluation Potential savings: : ~ 145 m³ per month
Due date: August/12 Responsible: Alex (Utilities)Investment: on evaluation Potential savings: on evaluation
17 | CIGE | 2011
QUERIES ?
...and warm thanks to Josef Postl for his continuous support!
Thanks for your patience...