Fingleton
White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
Fingleton
White & Co Ltd
ENGINEERS
& PROJECT MANAGERS
BRIDGE STREET CENTRE,
PORTLAOISE,
IRELAND
Tel: 0502 21010
Fax: 0502 2 23 82
Contact: John Fingleton
john.findeton@fingleton.ie
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
INTEL IRELAND
SUSTAINABLE ENERGY REPORT
Co
ns
en
GLOSSARY
OF TERMS ..........................................................................................
EXECUTIVE
1.0
SUMMARY
............................................................................
2.0
INTRODUCTION
.........................................................................................
3.0
INTEL ENERGY PROFILE..
........................................................................
4.0
COMBINED
HEAT AND POWER (CHP) STUDY.. ....................................
5.0
ENERGY CONSERVATION..
......................................................................
6.0
RENEWABLE
ENERGY TECHNOLOGY..
.................................................
A
ENERGY BALANCE
ESTIMATION..
.............................................................
B
LINKS AND REFERENCES
............................................................................
C
CALCULATIONS
.............................................................................................
2
3
3
3
3
3
3
3
3
3
EPA Export 25-07-2013:15:37:20
&
Fingleton
White
Intel Iselcmd
Date: 05/06/03
Sustainable Energy Report
GLOSSARY OF TERMS
AHU
BNE
CCGT
CER
FAB
HCV
HVAC
IF0
LCV
LIEN
NCS
PES
Attachment
G Intel SustaimBle
ns
en
DoELG
EPI
Co
COP
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
CHP
Air Handling Unit
Best New Entrant
Paper in which the CER (Commission for Energy Regulation)
identifies the price it believes the newest entrant into the Irish
electricity generation market, employing the best technology
will charge (2003 Price 4.7c/kWh)
Combined Cycle Gas Turbine
Combination of simple cycle gas turbine generator with waste
heat boiler raising steam which produces electricity in a steam
turbine generator.
Commission for Energy Regulation
Regulator of Gas and Electricity industries in Ireland
Combined Heat and Power
Defined in Irish Law (SI 25 1999) as “the simultaneous
production of utilisable heat and electricity from an integrated
thermo-dynamic process where the overall process operating
efficiency, based on the gross calorific value of the fuel used
and defined as the ratio of energy output usefully employed to
the energy input, is greater than 70 per cent.. .”
Coefficient of Performance
Output of refrigeration plant in kW divided by Input of energy
into refrigeration plant in kW
Department of Enterprise and Local Government
Energy Performance Index
Published target against which members of the LIEN (Large
Industry Energy Network) measure their performance in energy
efficiency. Base Year is taken as 100.
Semiconductor Wafer fabrication facility. There are 3 No.
FABs at Intel Leixlip, FABlO, FAB14 and FAB24 (under
construction). FAB24E may be constructed in the future.
Higher Calorific Value (of fuel)
Heating Ventilation and Air Conditioning
Irish FAB Operations, name given to FAB 10 and FAB 14
combined.
Lower Calorific Value (of fuel)
Large Industry Energy Network
Grouping of large energy users publishing and measuring their
performance against annual targets in energy efficiency.
National Climate Strategy
Irish national strategy to meet Kyoto Protocol commitments.
Public Electricity Supplier
In the context of this report, the published price the ESB will
charge for electricity.
Energy
Study
Page 2 of 43
EPA Export 25-07-2013:15:37:20
&
Fingleton
White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
Public Service Obligation
Levy charged on the electrical maximum import capacity
booked. The levy is designed to enable the ESB to ensure that
Ireland has reasonable self-sufficiency in electricity generation
by maintaining
a percentage of indigenous peat fired generation
and to help protect the environment by promoting the use of
renewable, sustainable and alternative energy sources.
Relative Humidity
RH
Second Step Electricity
In the PES tariff day units are charged at 2 rates. The first step
units are charged at a rate of 7.35c/kWh in Winter and
7.OOc/kWh in Summer. The number of first step units in each
billing period is determined by the Max Demand in kW
multiplied
by 350.
The remaining day units are charged at the second step rates of
4.92c/kWh in Winter and 4.6Oc/kWh in Summer.
SE1
Sustainable Energy Ireland
Formerly the Irish Energy Centre, is Irelands national energy
authority.
SOFC
Solid Oxide Fuel Cell
Sustainable Energy
The Department of Communications
Marine and Natural
Resources Green Paper on Sustainable Energy identifies that a
sustainable energy policy should:* ensure security of energy supply in order to
support economic and social development while
protecting the environment;
l
maximise efficiency of generation and
emphasise the use of renewable resources;
l
promote a culture of energy conservation by all
users;
l
minimise emissions of greenhouse gases and
other pollutants, both by clean generation and by
sustainable consumption levels in all sectors;
and
l
maintain local air quality and limit and reduce
the Irish contribution to regional and global
environmental
problems
TUoS
Transmission Use of System
Charges applied for provision of access to the electrical
transmission network
WACC
Weighted Average Cost of Capital
Average return on capital used by the CER (Commission
for
Energy Regulation)
for calculation
of the BNE (Best New
Entrant) electricity price.
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
PSO
Attachment G Intel Sustainable Energy
Shady
Page3 of43
EPA Export 25-07-2013:15:37:20
Intel Ireland
Sustainable Energy Report
1.0
EXECUTIVE
Date: 05/06/03
SUMMARY
Intel Ireland Limited
(Intel) operates an integrated circuit manufacturing
facility in Leixlip Ireland, IPC Licence (No. 589), which includes two existing
factories (FABlO & FAB14) plus a new factory (FAB24) that will be ramping
production in 2003. Section 5.18 of the IPCL states:
“. . . the licensee
shall
submit
a detailed
proposal
for
the
implementation
of the most sustainable energy solution for the site.
This proposal should include as a minimum
an assessment of the
viability
of installing
CHP. In investigating
the most sustainable
energy solution for the site the licensee will consider all the
environmental
impacts including the impact of NOx emissions from the
site. Following
approval of this proposal by the Agency, the most
sustainable energy solution for the site will be operational
no later
than I January 2005”
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Intel engaged Fingleton White to perform this independent
assessment in
support of the IPCL proposal.
This study demonstrates the following:
l
The energy consumption at the Intel site is projected to grow from
25SGWh of power and 123GWh of natural gas to 532GWh &
205GWh through the study timeframe.
l
A Combined Heat & Power Plant is not an economically
viable
sustainable energy solution due to
o the high ratio of electric power to thermal energy consumption
and poor thermal load factor.
o redundancy of electric and thermal generation required to meet
reliability constraints.
l
Each of the CHP options examined will increase local fuel
consumption and local emissions. This would be balanced by a net
reduction in global CO2 emissions (in all cases) and NOx emissions
(except in Gas Engine CHP).
In all cases the installation of CHP at Intel Ireland would significantly
increase lectricity costs.
Electricity
Local NOx
{
costs
Tonnes/annum
Tonnes/annum
Tonnes/annum
Tonnes/annum
(relative to
Independent
Supplier)
Gas
Engine
CHP
Gas
Turbine
+19%
+377
(t-1 100%)
+20%
+20
(+60%)
+281
(+926%)
Attnchnent
G Intel Sustainnble
Energy
Study
+328
(+400%)
(-7i;
-2s
(-8%)
+42,535
(+I 16%)
-25,110
(-24%)
+24,164
(+66%)
- 10,302
(-14%)
+308,709
(+840%)
-106,913
(-23%)
Page 4 of 43
EPA Export 25-07-2013:15:37:20
&
Fingieton
l
l
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
Renewable energy solutions are not attractive for the Intel Ireland site.
Due to the scale of the Intel Ireland site load of over 520GWh per
annum and the relative lack of scale of the renewable sector in Ireland
it is not possible to supply the site load with offsite renewables. In
common with all other customers of the electricity grid in Ireland,
through payment of the Public Service Obligation levy, Intel Ireland is
supporting the renewable sector in Ireland.
Intel Ireland has an established aggressive energy conservation
program, with dedicated resources. Corporate funds are specifically
made available for implementing
energy efficiency measures. Locally
more than 200 potential opportunities are under investigation or have
been implemented
in the last year alone. This is a continuous
improvement
process.
The new factory (FAB 24) will employ the latest technology in
manufacturing
to reduce energy consumption per unit of production.
The manufacture of 300mm wafers will commence in FAB 24. These
wafers are over 200% larger in area than 200mm, which is
manufactured in FablO and Fab14. They will improve the site energy
efficiency as measured by Energy Performance Index (EPI) but
contingent on the site running to projected full capacity for a
significant part of the each year.
l
ns
en
l
The EPI (Energy Performance Index, the published target against
which members of the Large Industry Energy Network measure their
performance in energy efficiency) of the Intel Ireland site has reduced
from 100 in the base year of 1995 to 63.64 in 2002.
It is anticipated that in time, SOFC/GT Hybrid CHP Systems (Solid
Oxide Fuel Cell / Gas Turbine) may make CHP commercially
attractive in the semi-conductor
industry. Such units are not yet
available in the MW range that would be required in Intel and it is
expected that it will be several years before such technology is both
proven and commercially
attractive.
Co
l
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
l
White
The primary factors which
at the site include:
electricity price, gas price,
regimes and developments
Should any of these factors
sustainable energy solution
affect the most sustainable
energy solution
possible carbon tax and emissions trading
in the renewable energy market.
alter significantly,
their impact on the most
for the site should be assessed.
The most sustainable energy solution, based on the study is continued
conservation activities and manufacturing
process improvements.
Attachment
G Intel Sustainable
Energy
Shady
energy
Page 5 of 43
EPA Export 25-07-2013:15:37:20
Intel Ireland
Sustainable Energy Report
2.0
Date: 05/06/03
INTRODUCTION
Fingleton White have been engaged by Intel Ireland Limited
to prepare an
engineering
study to support a proposal to the Ireland EPA for the most
sustainable energy solution that would be operational by January 2005
The engineering study utilised historical energy consumption
for the existing
factories (FABlO
& FAB14) provided by the site plus projected energy
consumption
of the new factories (FAB24 & FAB24E)
and estimated
production levels for the next 5 to 10 years. Fingleton White perfornled an
independent assessment of the energy utilitsation from the data to confirm the
future energy consumption.
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Based on the energy consumption estimates a CHP study was performed using
two alternatives
one employing
reciprocating
engine technology
and one
The
study
also
defines
the
projected
employing
gas turbine technology.
increase in emissions at the site from the additional natural gas consumption.
Fingleton White then provided independent estimates of renewable energy
options to compare the costs against the cost of grid power in the unregulated
power industry in Ireland
Co
ns
en
Although Fingleton White performed no energy audit, sufficient data was
made available to the study team to understand the energy consumption
and
the conservation efforts being undertaken by the sustaining operations.
Attm+ment G Intel Sustainnble Energy Study
Page 6 of 43
EPA Export 25-07-2013:15:37:20
&
Fingleton White
ENERGY
Intel Ireland
Sustainable Energy Report
3.0
INTEL
3.1
STUDY METHODOLOGY
Date: 05/06/03
PROFILE
In order to evaluate the viability of CHP at the site is necessary to accurately
identify the heat and electricity loads at the site. These loads are measured and
established for the existing FAB operations.
The methodology
for estimating the additional loads due to FAB 24 operation
is outlined below:
l
Examine
existing electrical
loads for FAB 10 & 14
l
Examine
existing
electrical
heat loads for FAB 10 & 14
l
Examine
existing
electrical
cooling
l
Develop
model for heating load for FAB 10
l
Apply this model to FAB 24 to calculate FAB 24 heating load
ot
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
Apply FAB 10 & 14 electricity
FAB 24 electrical load.
load profile
to FAB 24 to calculate
Co
ns
en
l
he
ru
se
.
load for FAB 10
Attachment G Intel Sustainable Energy Study
Page 7 of 43
EPA Export 25-07-2013:15:37:20
EPA Export 25-07-2013:15:37:20
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ns
en
Co
se
ru
he
ot
.
&
Fingleton
Intel Ireland
Sustainable Energy Report
White
The actual heat loads for FAB 10 and FAB 14 are tabulated
calculated heat load for FAB 24 and FAB 24E
Average
Gas Load
kW
7,320
6,740
9,349
1,828
FAB
FABlO
FABl4
FAB24
FAB24E
Average
Heat Load
kW
5,490
5,055
7,012
1,371
Date: 05/06/03
below along with the
Area
m2
95,127
74,979
118,670
17,723
FAB lo,14 & 24
se
ru
Average
Heat
Load
kW
10,545
he
Existing
Near
Future
Potential
Future
Average
Gas
Load
kW
14,060
ot
Comment
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
Stage
.
The calculated heat loads are added to the existing loads to give the expected heat
loads at various stages of development tabulated below:
N/A
23,410
17,557
78%
25,238
18,928
83%
N/A
Co
ns
en
The load factor is calculated from the average heat load of the facility, taking into
account the expected monthly variations. The higher the load factor the greater the
amount of the waste heat from the CHP is usefully employed on site.
The load factor is not shown for the CCGT CHP option as only the amount of steam
required for heating is bled off the stream turbine, the remaining steam passes through
the steam turbine and condenser.
See Appendix
A for details of calculations.
The Intel calculation for the Average annual heat load for FAB 10, 14 & 24 is
22,167kW. This figure is based on monthly estimates of the numbers of installed
boilers that will be running at full output. Operationally
it is likely that the numbers of
boilers running per month is the correct figure (4 in November-March,
2 in JuneAugust and 3 all other months), however it is not expected that they will be running at
full output.
The possibility of installing Absorption Chillers onsite in order to increase the site
heating load was discounted due to the low COP of Absorption Chillers (and the
consequent high cost of chilling) and space restrictions at the Leixlip site. See
Appendices for details.
Energy conservation programmes are ongoing at the site, should these continue to be
successful in reducing the site heat load, they will reduce the attractiveness of CHP at
the site.
Attachment G Intel Sustainable Energy Study
Page 9 of 43
EPA Export 25-07-2013:15:37:20
Intel Ireland
White
ELECTRICAL
LOAD ESTIMATION
The methodology
Establish existing FAB 10 & FAB 14 electrical
different substations.
Apply the same load profile to FAB 24 substations where appropriate.
FAB24 load to the existing
figures are tabulated
FAB lo&
14
Utilisation
%
Usage
Note 2:
Note 3:
Note 4:
Note 5:
& 14
below:
FAB 24
Utilisation
%
Note 1
Note 2
FAB 24
Installed
Capacity
kVA
Note 3
FAB 24
Average
Load
KW
Note 4
34%
49,000
16,878
31%
31%
32,200
10,057
33%
33%
4,900
N/A
NJA
ns
en
34%
Co
Utility &
Process
Energy
Centre
Office
Nitrogen
Plant
TOTAL
FABlO
.
Add the projected
consumption.
The resulting
Note 1:
load profile across
se
l
the future load due to FAB 24 is as follows:
ru
l
for estimating
he
l
Date: 05/06/03
ot
3.3
Fingleton
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
&
The utilisation factor for each set of substations is taken as the average
load divided by the installed capacity for each set of transformers. This
figure is measured for the FAB 10 and 14 utility and processes, energy
centres and offices.
The FAB 24 utilisation factor for each set of substations is taken to be
the same as the FAB 10 & 14 processes.
(The utilisation factors are maintained in the order of 33% as sufficient
spare capacity is installed to maintain redundancy levels to ensure
99.999% availability)
The installed capacity of the transformers for each of set of substations
is shown.
The average load is taken as the installed capacity multiplied
by the
utilisation factor.
The utilisation factor for FAB 24 Nitrogen cannot be calculated from
the existing nitrogen utilisation. The figure used is the Intel estimated
usage.
EPA Export 25-07-2013:15:37:20
&
Fingleton
White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
The actual electricity loads for FAB 10 and FAB 14 are tabulated below along with
the calculated electricity load for FAB 24 and FAB 24E
Of the total electricity consumption on site, it is taken that only part of
this electricity infiltrates the buildings as heat (e.g. none of the
electricity consumed in the energy centres, water, nitrogen and various
ancillary plants infiltrate the buildings as heat).
The Average Electricity Heat Gain is used in the Heat load calculation
and modelling.
As information
on the transformer ratings to be installed for FAB 24E
was not available, the electricity load for FAB 24E was calculated on a
W/m’ basis using the FAB 24 figure of 258 Wim2.
Note 2:
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Note 1:
Co
ns
en
The calculated electricity loads are added to the existing loads to give the expected
electricity loads at various stages of development tabulated below:
The estimated average site load of 60,118kW for FAB 10, 14 & 24, with a booked
capacity of 70MVA, corresponds to the Intel calculated capacity estimate of 77MVA.
Attachment G Intel Swainable
Energy Study
Page 11 of 43
EPA Export 25-07-2013:15:37:20
&
3.4
FMgleton
White
ELJWTRICAL
Intel Ireland
Sustainable Energy Report
AND HEAT
LOAD
Date: 05/06/03
SUMMARY
The actual heat and electricity loads for FAB 10 and FAB 14 are tabulated below
along with the calculated heat and electricity load for FAB 24 and FAB 24E
FAB
Average
Electricity
Load
kW
13,271
16,186
30,661
4.189
5,490
5,055
7,012
1.371
he
ru
se
.
FABlO
FAB14
FAB24
FAB 24E
Average
Heat Load
kW
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
The calculated heat and electricity loads are added to the existing loads to give the
expected heat and electricity loads at various stages of development tabulated below:
Stage
Comment
Average
Electricity
Load
Co
ns
en
kW
Average
Heat Load
kW
Attachment C Intel Susrainable Energy Study
Page 12 of 43
EPA Export 25-07-2013:15:37:20
&
Fingleton
Intel Ireland
Sustainable Energy Report
White
4.0
COMBINED
HEAT
AND POWER
4.0
CHP Analyses Summary
(CHP)
Date: 05/06/03
STUDY
The summary sheet on the following page outlines the situation with respect to
the installation of CHP at Intel Ireland.
The table identifies the installed thermal and electrical capacities and capital
costs.
The Installation
of CHP at the Intel Ireland is not economically
attractive.
The installation of 6 No. (19.2MW total) Gas Engine based CHP units (sized
to match the heat load) would result in an average cost of electricity generated
at the site of 5.952cfkWh.
ru
se
.
The installation of 2 No. (1lMW total) Gas Turbine based CHP units (sized to
match the heat load) would result in an average cost of electricity generated at
the site of 6.OOOc/kWh.
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
The installation of 3 No. CCGT based CHP units (36.7MW each, sized to
match 3 X 50% of the electrical load) would result in an average cost of
electricity generated at the site of 5.841c/kWh.
Co
ns
en
The estimated independent supplier unit price is 4.996c/kWh.
Each of the three CHP options is significantly higher than this price.
Attachment G Intel S~rstainnble Energy Study
Page 13
of 43
EPA Export 25-07-2013:15:37:20
Fingleton
White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
ns
en
c/kWh
kWh
c/kWh
%
c/kWh
%
c/kWh
%
Co
Site Average Unit Price
Site Units
PES Unit Price
5.430
Site Generated Unit price increase over PES
BNE Delivered to site Unit Price
5.475
Site Generated Unit price increase over BNE Delivered
Estimated Independent Supplier Unit Price
4.996
Site Generated Unit price increase over lndep Supplier
lndexation of Generated Units Site Average Price
Indexed to Gas
Indexed to CPI
Fixed
Total
Heating Units Price
Heating lndexation
Indexed to Gas
Total
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
&
5.695
532,773,178
5.593
532,773,178
5.957
532,773,178
9.6%
10.5%
7.6%
8.7%
9.6%
6.7%
19.1%
%
49%
25%
26%
100%
c/kWh
2.916
1.488
1.548
5.952
%
100%
c/kWh %
1.885 100%
1.885
c/kWh
%
56%
18%
26%
100%
1.885
20.1%
c/kWh
3.360
1.080
1.560
6.000
%
61%
10%
29%
100%
16.9%
c/kWh
3.563
0.584
1.694
5.841
c/kWh %
1.885 100%
1.885
c/kW h
1.885
1.885
1.885
1.885
EPA Export 25-07-2013:15:37:20
&
Finglefon
4.1
Intel Ireland
Sustainable Energy Report
White
Date: 05/06/03
Payback return
Using the electricity and heat loads calculated above the viability of installing
various CHP options in Intel Ireland was calculated.
The methodology used was as follows:
l
Estimate the capital and operating costs of the installations
l
Sell the heat at the energy cost of conventional boilers
l
Calculate the electricity cost required to achieve required simple
payback
The simple payback required was calculated based on the Weighted Average
Cost of Capital used in the BNE calculation used by the CER in 2003. In order
to calculate the equivalent straight line simple payback, the inflation factor
used in the CER calculations was removed.
WACC
Calculation
4Real cost of debt (rd)
se
he
ot
5.63%
2.75%
0.00%
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
Cost of Debt
I Nominal Risk Free Rate
2Debt risk premium
Blnflation
.
Value
%
ru
Description
1+2-
8.38%
13.66%
2.00
21.70%
12.50%
73Pre-tax cost of equity (rc)
24.41% 11*(lOO% + 1,
Co
ns
en
Cost of Equity
5Nominal Risk Free Rate
Glnflation
7Real risk free rate
8Equity risk premium
9Expected market rate of return
lOEquity Beta
7 7 Post-tax cost of equity
IPTax rate
WACC
74Gearing (g)
5.63%
0.00%
5.63%
5-
8.03%
7+
7+ 10*(9-
70%
75WACC = g * rd + (l-g) * rc
Annual Repayment required per 1000
76borrowed over 15 years at this rate
17Simple Payback
13.19%
E (156.25)
6.400 - l/(16
* 100
Thus the straight line simple payback required is 6.40 years.
Attachment
G Intel Sustainable
Energy
Shady
Page IS of 43
EPA Export 25-07-2013:15:37:21
White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
CHP Operation
GRID
1lOkV
LINE
Q
I-------------------------------------------------------------
i
I
:
I
i
i
I
I
EXISTING
LOAD
EXISTING
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
POWER
ELECTRICAL
HEATING
INFRASTRUCTURE
INFRASTRUCTURE
CAPABLE
CAPABLE
OF MEETING
OF MEETING
SITE
SITE LOAD
CHP ELECTRICAL
CAPACITY
IN ADDITION
TO GRID
CHP HEATING
CAPACITY
IN ADDITION
TO ENERGY CENTRES
ns
en
4.2
Fingleton
Co
&
CHP electrical and heating capacity is in addition to existing installed
capacity. Semi-conductor
wafer fabrication facilities require a 99.999%
availability
in order to avoid the loss or potential loss of very valuable
production. In order to achieve this availability,
sufficient capacity must be
installed and maintained in operation that if a single unit trips, there is always
sufficient capacity installed and running to maintain continuity of supply
without interruption. Thus in the CHP options which are sized to match the
heat load, there are always sufficient boilers running in the existing energy
centres to maintain supply. The CCGT CHP the facility it is sized to match 3
by 50 % of the electrical load, thus if one unit trips the remaining units
continue to supply the site without interruption.
Both the installation of excess capacity and the continuous running of excess
capacity decrease the viability of CHP but the operational availability
of
99.999% must be met.
The Gas Engine and Gas Turbine based CHP facilities are sized to match the
site heat load.
In operation the majority of the heat requirements of the site are satisfied by
the CHP facility. For the Gas Engine CHP, 3 X 1,OOOkW of site heating is
supplied by existing boilers. For the Gas Turbine CHP, 4 X 1,OOOkW of site
EPA Export 25-07-2013:15:37:21
Fingle ton White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
heating is supplied by existing boilers. These boilers are kept running to
ensure continuity of supply in the event of the tripping of a single CHP unit.
Only part of the electricity load is supplied by the CHP facility (site load is
61MW, Gas Turbines output 1 lMW, Gas Engines output 19MW). The
majority of the site load is still supplied by the grid at the PES price.
During downtime periods the site heating load is supplied by the Energy
Centre boilers and the full site electricity load is supplied by the grid. The full
costs of maintaining
the backup grid electricity supply has been integrated into
the financial model.
The CCGT based CHP facility is sized to match 3 X 50% of the site electricity
load. This is in order to ensure the continuity of supply required by a
semiconductor fabrication facility, however this requirement has the effect of
increasing the capital cost of the CHP facility and reduces the viability of
CHP.
Co
4.7oodkwh..
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
In operation, the heat requirements of the site are fully satisfied by the CHP
facility. In the event of the tripping of a single CHP unit the remaining units
will supply the site heating load. The full electricity load is supplied by the
CHP facility (site load is 61MW, CCGT output is 1 lO.lMW
installed,
73.4MW with two units running).In normal operation the CCGT is exporting
to the grid.
If two or more units are not operating the site heating load is supplied by the
Energy Centre boilers and the site electricity load is supplied by the grid. The
full costs of maintaining
the backup grid electricity supply has been integrated
into the financial model. For comparison purposes it is assumed that the
downtime electricity is purchased at the PES tariff.
The value of the exported electricity is set at the 2003 BNE price of
Attachment G Intel Sustainable Energy Study
Page I7 of 43
EPA Export 25-07-2013:15:37:21
EPA Export 25-07-2013:15:37:21
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ns
en
Co
se
ru
he
ot
.
&
Fingleton White
Intel Ireland
Sustainable Enerav Reuort
Date: 05/06/03
Thus the average cost per unit of electricity would be 5.695 c/kWh with CHP
installed up from an estimated cost of 5.430 c/kWh for PES supply without
CHP.
Based on the Wartsila 220SG the emissions
NOx 500mg/Nm3
CO 650 mg/Nm3
Exhaust Flow 17,398 Nm3/h (21,319kg/h)
Exhaust Temp 120 Deg C
Noise 70DBA at lm
Global NOx
Tonnes/annum
Local CO2
Tonnes/annum
Global CO2
Tonnes/annum
se
.
Local NOx
Tonnes/annum
impacts of this CHP option are tabulated
+377
+328
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
+19.1%
ot
he
Electricity
costs
(relative to
Independent
Supplier)
and environmental
ru
The economic
below:
data is as below:
+42,535
-25,110
Co
ns
en
The facility would be spread over two locations, one adjacent to FAB 10 &
FAB 14 Energy Centres and one adjacent to FAB 24 Energy Centre.
The facility could be operational within fifteen months of placement of order.
Attachment
G Intel Sust&nble
Energy
Study
Page 19
of 43
EPA Export 25-07-2013:15:37:21
EPA Export 25-07-2013:15:37:21
se
Co
n
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
nt
o
se
.
ru
he
ot
&
Fingleton
Intel Ireland
Sustainable Energy Report
White
Date: 05/06/03
Exhaust Temp 130 Deg C
Noise 70DBA at lm
The economic
below:
Electricity
costs
(relative to
Independent
Supplier)
and environmental
Local NOx
Tonnes/annum
+20.1%
+20
impacts of this CHP option are tabulated
Global NOx
Tonnes/annum
Local CO2
Tonnes/annum
-4
Global CO2
Tonnes/annum
+24,164
-10,302
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
The facility would be spread over two locations, one adjacent to FAB 10 &
FAB 14 Energy Centres and one adjacent to FAB 24 Energy Centre.
The facility could be operational within fifteen months of placement of order.
Attachment
G Intel Sustainable
Energy
Study
Page 21
of 43
EPA Export 25-07-2013:15:37:21
EPA Export 25-07-2013:15:37:21
se
Co
n
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
nt
o
se
.
ru
he
ot
&
Fingleton
Intel Ireland
Sustainable Energy Report
White
Based on the Rolls Royce RB211 the emissions
NOx 50mg/Nm3
CO 50mg/Nm3
Exhaust Flow 261,257 Nm3/h (88.90kg/s)
Exhaust Temp 120 Deg C
Noise 70DBA at lm
The economic
below:
Electricity
costs
CCGT
CHP
and environmental
Local NOx
Tonnes/annum
+28 1
+16.9%
Date: 05/06/03
data is as below:
impacts of this CHP option are tabulated
Global NOx
Tonnes/annum
Local CO2
Tonnes/annum
-28
+308,709
Global CO2
Tonnes/annum
-106,913
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
The facility would be located north of the existing FAB 10 & 14 Energy
Centres. This is a major facility, which is likely to raise objections in the
planning process, due to it being perceived as a power station rather than CHP.
Should permission be received, the facility could be operational within twenty
four months of placement of order.
Attachment
G Intel Sustainable
Energy
Study
Page 23 of 43
EPA Export 25-07-2013:15:37:21
EPA Export 25-07-2013:15:37:21
se
Co
n
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
nt
o
se
.
ru
he
ot
Fingleion
5.0
Intel Ireland
Sustainable Energy Report
White
Date: 05/06/03
ENERGY CONSERVATION
It is through the ongoing energy reduction and monitoring
and targeting
programmes that Intel Ireland has made and can continue to make its greatest
contribution
to achieving a more sustainable energy solution for the Leixlip
Site.
5.1
Existing Energy Reduction Programme
Sustainable energy solutions involve
utilising renewable energy sources.
reducing
energy consumption
as well as
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
As a member of the Large Industrial Energy Network at Sustainable Energy
Ireland, Intel Ireland is committed to pursuing energy efficiency as a corporate
objective
and to publicly
communicating
their annual
targets and
performances in a transparent manner through the annual reports of the LIEN.
The basic principle of the Energy Performance
Index (EPI) is that it is a
measure of energy consumption
per unit of output, allowing for production
and other variations, by relating the figures to a base year. That is, the EPI
represents the overall productivity
of energy use by a company for each year,
relative to a base year, normally when the company joined the LIEN.
Since the base year of 1995 and through Intel Irelands investment in
approximately
200 individual energy projects, the Energy Performance Index
(EPI) has reduced from 100 (1995 as base) to a figure of 66.29 in 2001 and a
target of 63.64 for 2002. This reduction places Intel in the top 20% of
members of the network.
Among the original 1995 members Intel Ireland has achieved the fourth largest
decrease in the EPI.
The commitment
of Intel Ireland to energy reduction is borne out by energy
reduction proposals being discussed at weekly engineering meetings. The
commitment
of Intel Ireland to energy reduction extends beyond engineering
staff. In large organisations such as Intel Ireland suggestions/improvements
from staff can often remain unheard, in order to counteract this Intel have
implemented
a cost savings suggestions web page on the company intranet.
Here employees can make their suggestions and track their implementation.
The energy reduction group has its own web page where the progress of
individual projects can be tracked.
Sustainable Energy Ireland have identified nine areas of focus in the drive for
increased energy efficiency for more sustainable energy solutions. The areas
and the relevant energy reduction projects can be seen below:
l
Attachmenr
Boiler
C Intel Sustainnble
Efficiency Improvements
Projects currently in progress include the installation of
Variable Speed Drives to reduce energy consumption in the
boilers and a project to replace mechanical linkages in the
boiler controls to allow more accurate control of the firing rate.
Removal of linkages for boilers yield 7% reduction in
emissions and gas consumption due to combustion efficiencies.
Energy
Study
Pnge 25 of 43
EPA Export 25-07-2013:15:37:21
&
Fingleton White
l
Intel Ireland
Sustainable Efaergy Report
Date: 05/06/03
CHP
This report incorporates the fourth local site CHP study. There
have been numerous studies on other international
Intel sites.
l
Compressed Air Energy Reduction Programmes
Projects currently under way include leak testing and
evaluation in IR5 in an effort to reduce consumption. Cross site
air compressor pressure reset to allow for lower energy
consumption in the production of compressed air and
optimisation
of the use of instrument air. There have been a
number of interconnects between compressor systems installed
which allow sharing of load and reduction in energy. Time
control of IRl compressors realised savings.
Energy Reduction Programmes
Reduction in lighting energy consumption in IR3 warehouse.
Lighting on site is manually and automatically
controlled by
timeclocks, building management systems , PIR detectors,
photocells and dedicated lighting zone controllers. There is
continual improvement
of control.
Monitoring
and Targeting
Intel has a comprehensive Energy monitoring network. This
consists of electricity supplier metering, electrical substation
and distribution board metering over a network, and portable
energy meters. Gas metering is provided by gas supplier.
Energy consumed by chilling and heating is monitored through
flow-meters and temperature probes. This is tracked through
programmable
logic controllers to a historical database. There
is a continued investment on site in monitoring with an upgrade
to the energy meters, the network and other relevant
instrumentation
across site. The equipment provides both
instantaneous and historical data.
Co
l
Lighting
ns
en
l
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
l
Clean Room Energy Reduction Programmes
Intel Corp. carried out detailed studies to reduce clean room air
change rates from 85cfm (cubic feet per minute) to 72cfm. This
programme was implemented
in 2002. Further studies are
ongoing in an effort to reduce this figure to 65cfm.
A utility team takes the supplier invoices and compares the
billed amount against projected targets. This is carried out
monthly. This team reports to senior management.
There is a person employed fulltime and dedicated to Energy
Conservation who co-ordinates the energy/utility
reduction
programme. The Energy/Utility
Reduction Programme supports
idea generation, viability, scoping and costing, implementation
and verification of savings.
Attnclment G Intel Sustnirmble Energy Study
Pnge 26 of 43
EPA Export 25-07-2013:15:37:21
&
Fingleton
White
Intel Ireland
Sustainable Energy Report
Funding
Fund.
if required from Corporate
Utilities
Date: 05/06/03
Conservation
ru
se
.
A System Improvement
Team (SIT) is a cross department team
- Engineering, Maintenance, Operations and Partner Suppliers.
SIT members have carried out projects to reduce energy in
addition to normal duties. All projects are tracked on an
Intranet database. After implementation
of a project that will
yield electrical savings the weekly consumption of the relevant
meter can be checked to verify the reduction. Project owners
measure/calculate
expected reduction. After implementation
these reductions are verified.
Each project/activity
to reduce energy would be transferable
across global sites e.g. putting time control on office air
handling units so that they turn off when the building is
unoccupied
The nature of System Improvement
Teams means participation
across all groups including suppliers to Intel.
ot
he
Refrigeration
Energy Reduction Programmes
Projects currently under way include the automation of the
FAB 10 chiller operation to allow for more efficient running of
the plant through better response to site loads.
Various projects are underway to reduce the energy
consumption required to generate refrigeration including
removal of prefilters in FAB 10, general site-wide mixing
damper overhaul and optimisation
of the bypass flow in FAB
14 Chiller.
Other projects to reduce the demand for refrigeration on site
include further studies to optimise the FAB make up air
requirements, office and kitchen reduction in AHU run hours.
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
l
l
l
Attachment
Installation
of Variable Speed Drives
Intel Ireland have installed VSDs (Variable Speed Drives) in
the majority of its equipment where appropriate. Individual
projects are examined on an ongoing basis. The majority of Air
Handling units, the largest consumers of power, have been
fitted with VSDs.
Installation
of Building Energy Management
Systems
Intel Ireland have installed Building Energy Management
systems and carry out regular monitoring
and targeting of
consumption. Historical data is stored on a computer database.
G Intel Sustainable
Energy
Study
Page 27 of 43
EPA Export 25-07-2013:15:37:21
EPA Export 25-07-2013:15:37:21
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ns
en
Co
se
ru
he
ot
.
Finglefon Whiie
5.3
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
300mm wafer technology
In 2004 manufacture of 300mm wafers will commence in Fab 24. These
wafers are 225% larger in area than 200mm, which is manufactured in FablO
and Fab14. They will yield 240% increased printed die (individual computer
chips) than the 200mm wafer. This efficiency increase in manufacturing
output per wafer will improve the Energy Performance Index (EPI) from 2005
provided factory output remains at projected levels.
5.4
Design & Tools
he
Communication, employee involvement and management support
ot
5.5
ru
se
.
Intel has an ongoing commitment
to improving technology in existing
factories. Recently Fab 10 and Fab 14 has begun manufacturing
flash
technology on site, which required new tools to be installed. These tools are
more energy efficient than existing tools. Intel works with tool suppliers to
improve energy efficiency.
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
When energy reduction projects are carried out there is increased
communication
with customers e.g. lights being turned off outside of regular
work week. This activity means participation of occupants and users of the
area concerned. They then become more sensitized to utility reduction across
site and see that there is management support. By using the web based energy
savings suggestion tool, ideas are gathered and communicate
their
implementation.
Participation
in Sustainable Energy Ireland’s Energy Awareness Week
highlights activities both inside and outside of Intel.
Attachment G Intel Sustainable Energy Study
Page 29 of 43
EPA Export 25-07-2013:15:37:21
&
Fingleton
White
6.0
RENEWABLE
6.1
Summary
Intel Ireland
Sustainable Energy Report
Date:05/06/03
ENERGY TECHNOLOGY
~ Electricity
1 Price
I-.---ClkWh
Due to the scale of the Intel Ireland site load of over 52OGWh per annum and
the relative lack of scale of the renewable sector in Ireland it is not possible to
supply the site load with offsite renewables.
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
The installation of smaller scale renewable solutions would increase direct
costs, would not have any great impact on the overall energy consumption of
the site and would increase complexity and indirect costs.
In common with all other customers of the electricity
Renewable
energy solutions
Onsite Wind Power
are not attractive for the Intel Ireland
site.
Co
6.2
grid in Ireland, through
of the Public Service Obligation levy, Intel Ireland is supporting fuel
and the renewable sector in Ireland.
ns
en
payment
diversity
The disadvantages of installing onsite wind power at Leixlip include, low
estimated wind speed, planning difficulties and site location difficulties
amongst others.
The advantages include easy grid connection and a very visible investment
renewable energy.
The cost of the installation
order of fl5.2m.
of 3 No. 1.7.5hJW Wind Turbines
in
would be in the
A site average of 7m/s would result in a load factor of 21%. This means that in
an average year the turbines would produce 21% of the rated capacity.
The electricity charge the installation would require to obtain a simple
payback of 6.40 years is an average of 9.820 c/kWh.
The majority of the site electricity load would still have to be supplied by an
external supplier (taken as PES) and the wind turbine would be displacing
mostly the cheaper second step electricity.
The capacity and PSO charges would not reduce from pre wind turbine
installation
Attmhmerzt
levels.
G Intel Sustainable
Energy
Study
Page 30 of 43
EPA Export 25-07-2013:15:37:21
Intel Ireland
Sustainable Energy Report
6.3
Date: 05/06/03
Purchase of Ofisite Renewable Electricity
h-eland currently produces approximately
6% of its annual electricity
production from renewable sources. Approximately
800GWh is produced
from Hydro stations (mostly installed prior to 1960).There is little scope for
increasing the installed capacity or output of the Hydro sector in h-eland.
Approximately
400GWh is produced in windfarms (installed after 1992).
There have been a number of government incentive schemes to promote wind
in the last 10 years and a significant part of the PSO levy on all ESB bills is to
subsidise wind and other renewables. In effect therefore all consumers are in
fact already paying for renewable electricity. Based on booking a capacity of
70MVA the Intel Ireland PSO bill will be in the order of +Z400,000.
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
There are a number of independent suppliers of wind in the Irish market,
however these are primarily targeted at the small and medium enterprise
(commercial)
market. The current lowest price these suppliers sell electricity
at is 9.Oc/kWh compared to the current site price of 5.430c/kWh.
There are
currently over 20,000 of these “premium”
customers in the independent supply
sector. With an average consumption of 25 MWh per annum this represents a
market of 500 GWh per annum currently being supplied by renewable energy.
If Intel was to seek to be supplied solely (or indeed in any significant quantity)
with renewable energy, a number of obstacles would have to be overcome.
l
Co
ns
en
l
Renewable Energy suppliers would have to forgo the higher margins to
supply Intel at current prices
Renewable suppliers are allowed to balance their purchases and supplies
on an annual basis, they buy “top up” when the wind does not blow and
sell to “spill” when they have an excess” The balancing cost and supply
risk would have to be factored for such a large load.
The impact on the grid of 60 MW of renewable would be significant.
There would need to be at least another 60 MW of reserve and/or peak
plant available to cover shortfalls. A recent paper from CER regarding the
future of renewables suggests the imposition of a reserve capacity payment
on renewable energy to provide this back up.
The influence of a single large consumer would have a “skewing effect”
on the emerging green market which would allow the suppliers and
generators to set prices. A significant excess of demand over supply would
drive prices higher in the short term until more generation is available.
The uncertainty of the outcome of the forthcoming electricity market
revisions makes this option very risky in the short term.
l
l
l
Other than market and grid difficulties in supplying the Intel h-eland site with
renewable electricity, there are also capacity difficulties. The Intel load of over
520GWl-1 would require the installation of over 175MW of wind turbines in
Ireland. This is not a realistic option in a five year timescale as the total
installed by all developers over the last ten years was less than 140MW during
which time there were government incentive schemes with the specific target
of over 500MW.
Artaclzment
G Intel Sustainable
Energy
Study
Page 31 of 43
EPA Export 25-07-2013:15:37:21
&,
Fingleton
6.4
4.4.1
Intel Ireland
Sustainable Energy Report
White
Date: 05/06/03
Bio Fuels
Bio Diesels
The most popular
form of bio diesel used in the UK and Germany currently is
5% bio diesel and 95% standard diesel. This fuel does not necessitate any
alteration to the majority of existing diesel engines and in most cases reduces
particulate emissions. Section 5.9 of the Intel IPC Licence (No. 589) limits the
use of the onsite diesel generators to unplanned emergency and test purposes
only, this limitation
is unlikely to be lifted due to the use of bio diesel.
Section 5.14 of the Intel IPC Licence limits the use of diesel in the boilers to
unplanned accidental interruption of the natural gas supply or for test
purposes, this limitation
is unlikely to be lifted due to the use of bio diesel.
Wood, Paper & Cardboard Waste
The total annual mass of wood, paper and cardboard waste currently recycled
onsite is 387 tonnes per annum. At an LCV of 14.5MJ/kg this represents
approximately
1,600,OOO kWh per annum, which would raise heating of
147kW at an efficiency of 83.3%. This level of output does not justify the
significant capital investment involved in installing the extra boiler capacity.
6.5
Solar Energy/ Photo voltaics
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
6.4.2
Co
ns
en
The cost of installing photo voltaic cells in Intel Ireland has been estimated at
cl35 per 1OOW installed (approx 1 square foot). The average output in Ireland
is in the order of 10% of installed capacity, thus 1OOW installed will give an
output of 1OW on average. 1OOW installed capacity will generate 87.6kWh per
annum. In 6.40 years the cell would produce 560.64kWh, requiring a cost of
24.079c/kWh
in order to achieve this payback. This can be compared to the
estimated cost of 5.43 c/kWh for PES supply.
With an average ilTadiation of l,013kWh/m*/annum
in Ireland, in order to
supply the Intel Ireland load of approximately
52OGWh, over 500,00Om* of
panelling would need to be installed, taking up over 80 hectares of ground
(when installed at the optimum angle and spaced so as to avoid shadowing
each other).
Attachment
G Intel Sustflirlnble
hergy
Study
Page 32
of 43
EPA Export 25-07-2013:15:37:21
&
Fingleton
White
Intel Ireland
Sustainable Enerm Revort
Date: 05/06/03
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
APPENDICES
Attachment
G Intel Sustainable
Energy
Study
Page 33 of 43
EPA Export 25-07-2013:15:37:21
EPA Export 25-07-2013:15:37:21
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ns
en
Co
se
ru
he
ot
.
&
Fingleton White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
The figure that infiltrates the building is taken as the total less energy
centre, water, Nitrogen and various ancillary plant loads.
l
l
A.2
Personnel Gains
(Minor gains in this case)
Personnel Gains are taken as 1000 personnel per FAB.
Heating supplied
(Assumed to be the gas consumption by the raising efficiency of 75%)
The gas consumption is taken from the file Natural Gas.xls supplied by
Intel.
Heat lost from Building
The heat lost from the building
as follows:
Air Change Losses
(The heat lost when heated air is expelled from the building to be replaced
by air that must be heated to internal design temp)
Air Change Losses are taken from the generalised HVAC data supplied by
Intel related to the square area of each of the typical types of conditioned
space, Support Area and Office. Specific volumes of Makeup air for Clean
rooms was supplied by Intel.
Fabric Losses
(Based on wall and roof size, material and temperature
inside and outside)
The wall and roof areas are calculated as above.
difference between
Co
ns
en
l
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
l
is identified
A.3
Heat taken from Building
The heat taken from the building
l
is identified
as follows:
Net Cooling Load
(The total cooling load less the dehumidification
cooling required to
reduce the humidity of the make up air)
The Cooling Load is calculated from the file FAB 10 Chiller Loads R2.xls
supplied by Intel. The net cooling load is taken as the gross cooling load
less the estimated dehumidification
cooling required to reduce the
humidity of the make up air. The target relative humidity for each type of
building are as follows:
Clean room
22 Deg C 40% RH (Cool to 7 Deg C)
Office
22 Deg C 50% RH (Cool to 10 Deg C)
support
22 Deg C 60% RH (Cool to 14 Deg C)
The average dehumidification
load is calculated from hourly data from the
Met Office giving the number of occurrences of each wet bulb and dry
bulb temperature over a 20 year period for Kilkenny. From this data, the
Attaclment
G Intel Sustainable
Energy
Shrdy
Page 35 of 43
EPA Export 25-07-2013:15:37:21
&
Fing/eton
White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
time weighted average of all the temperature occurrences above 7 Deg C is
calculated. Thus the average dehumidification load for the clean room can
be estimated. Similarly for 10 and 14 Deg C.
Subtracting the Dehumidification cooling from the actual cooling load for
FAB 10 yielded a base cooling load of approximately 72% of the
calculated electricity load. This is the base load assumed for FAB 24.
A.4
FAB 10 Offices Calculation
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
See Table A. 1, next page.
Attachment
G Intel Sustainable
Energy
Study
Page 36 of 43
EPA Export 25-07-2013:15:37:22
White
Intel Ireland
Sustainable Energy Report
Heat to
Ext Temp
deg C
deg C
Actual
Actual
dT
dT
deg C
deg F
Date: 05/06/03
Off
Average
De Humid
Air
Air
Wall
Roof
Wall
Roof
Total
Total
AHU
DeHumid
Cooling
Change
Change
Losses
Losses
Solar
Solar
Gains
Losses
dT
Losses
Gain
Gain
degC
kW
kW
kW
kW
kW
dT
degC
kW
deg C
22
17.5
31.5
10
1.33
197
4.9
22
17.1
30.8
10
1.34
198
Mar
6.5
22
15.5
27.9
10
1.79
17.5
kW
.
4.5
Feb
kW
se
Jan
-2,587
-197
-466
0
-3,25C
17.1
-2,528
-192
-455
0
-3,176
264
15.5
-2,292
-174
-413
C
-2,879
2.56
379
13.8
-2,040
-155
-368
0
-2,563
3.34
494
12.0
- 1,774
-127
-301
c
-2,202
4.91
725
12.0
- 1,774
-92
-218
C
-2,085
ru
Fingleton
Apr
8.2
22
13.8
24.8
10
May
10.7
22
11.3
20.3
10
Jun
13.8
22
8.2
14.8
10
Jul
15.3
22
6.7
12.1
10
Aw
15
22
7
12.6
10
Sep
13.1
22
8.9
16.0
10
Ott
10.1
22
11.9
21.4
Nov
7.1
22
14.9
26.8
Dee
5.5
22
16.5
29.7
10
Average
W per m2
10
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
&
817
12.0
-1,774
-75
-178
10
68
78
-2,028
814
12.0
-1,774
-79
-186
10
68
78
-2,039
4.34
642
12.0
- 1,774
-1oc
-237
c
-2,111
10
3.10
458
12.0
- 1,774
-134
-317
C
-2,225
10
2.01
296
14.9
-2,203
-168
-397
C
-2,767
1.49
220
16.5
-2,439
-186
-439
C
-3,065
459
-2,061
-140
-331
10
68
13
-2,533
16
-70
-5
-11
C
2
0
-86
Co
ns
en
5.53
5.50
Table A.1
EPA Export 25-07-2013:15:37:22
,&-
Fingleton
Intel Ireland
Sustainable Energy Report
White
1 Date: 05/06/03
The total floor area of office relating to FAB 10 ( supported by the FAB IO
infrastructure) is 29,324 square meters.
The average monthly external temperatures for Phoenix Park are given in the
“Ext Temp” Column.
The target room temperature of 22 Deg C and the actual temperature
difference between internal and ambient are given in the next columns.
The “Off AHU” temperature is taken as the temperature it is required to cool
incoming air to, in order to achieve the correct relative humidity. Thus for
50% RH at 22 Deg C (0.008kg moisture/kg Dry Air) it is necessary to cool
incoming air to 10 Deg C. Thus for days with external temperatures greater
than 10 Deg C it is necessary to cool incoming air.
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
The “Average DeHumid dT” column gives the time weighted average of all
temperatures above the Off AHU temperature. This figure is calculated from
hourly data from the Met Office giving the number of occurrences of each wet
bulb and dly bulb temperature over a 20 year period for Kilkenny. Over a
twenty year period there was 1 hour with an average temperature of 14 Deg C,
29 hours with an average temperature of 13 Deg C, 195 hours of 12 Deg C aud
549 hours of 11 Deg C. Thus the time weighted average of all temperatures
above 10DegCis 11.33DegC.
For the given volume of Make up air this will give an Average DeHumidification cooling load. This DE-Humidification load is subtracted from
the measured cooling load to calculate the base cooling load (the heat removed
from the building, both from the process and from the HVAC system.
Co
ns
en
The Air Change losses are calculated as the heat lost in the air removed from
the building, to be replaced by heating the incoming air from ambient (or the
off AHU temperature) to room temperature.
The wall losses are calculated as the heat lost through the fabric of the walls of
all the office space.
The roof losses are calculated as the heat lost through the fabric of the roof of
all the office space.
Solar gains are an important factor in calculating the peak cooling load
required in a HVAC system but are not a major influence in Ireland on the
average HVAC loads and hence are only taken into account for July and
August.
The above calculations are similarly carried out for the Clean rooms and
support areas with the summation of the losses and gains calculated yielding a
table as described in Section 5.5.
A.5
FAB 10 Energy Centre Average Heating/Cooling Load
See Table A.2, next page
Attnchrnent G Intel Batnimble
Energy Study
Pflge 3S of 43
EPA Export 25-07-2013:15:37:22
Fingleton
Intel Ireland
Sustainable Energy Report
White
Date: 05/06/03
0
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
&
Dee
Average
W per m2
6
786
-8,493
-480
-1,553
(
10
1,497
-7,05I
-362
-1,171
‘
IC
-74
-4
-12
(
Table A.2
EPA Export 25-07-2013:15:37:22
&
Fingleton
White
Intel Ireland
Sastainable Enesgy Report
Date: 05/06/03
The de-humidification
cooling, the air change losses, the wall and roof losses
are the summation of the figures calculated for the office, clean room and
support areas supported by the FAB 10 infrastructure.
The wall and roof solar gains are the sum of figures calculated for the office,
clean room and support areas supported by the FAB 10 infrastructure.
The electricity gains are taken as the amount of the total electricity consumed
by the FAB that infiltrates the building. This is taken as the total electricity
consumption less energy centre, water, Nitrogen and various ancillary plant
loads.
The personnel gains are taken as the average gain from an occupancy of 1500
people averaged over 24 hours.
he
ru
se
.
The total gains are taken as the total heat into the office, clean room and
support buildings supported by FAB 10 infrastructure.
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
The Net cooling load is the total FAB 10 cooling load less the
dehumidification
cooling and is taken as the total heat removed from the FAB
10 supported buildings, this includes both process and HVAC cooling.
The total losses are taken as the total heat lost from the office, clean room and
support buildings supported by FAB 10 infrastructure.
Co
ns
en
The summation of the Total gains, net cooling and total losses for a single
month gives the heating required to maintain building temperature for the
given month.
This calculated figure can be compared to the actual heat load supplied
through the FAB 10 gas meter assuming a 75% HCV efficient
with the
Y7
average calculated being 60 w/m2 and the actual being 58 w/m
This model was then applied to the building area supported by FAB 24
infrastructure with the calculated heating load being added to the actual
heating load in FAB 10 and 14.
A.6
FAB 24 Energy Centre Average Heating/cooling
See Table A-3, next page
Attachment G htel Sustnirznble Bzergy
Shidy
Load
Page 40 of 43
EPA Export 25-07-2013:15:37:22
White
Intel Ireland
Sustainable Energy Report
De Humid
Cooling
Deg C
kW
Wall
5
79L
-12,387
-875 -2,00
(
eb
5
79:
-12,104
-855 -1,95(
(
lar
7
1,402 -10,972
-77!
(
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
m
1,93L - 10,046
-69~ -1.571
(
11
2,502
-8,987
-561 -1,29:
(
m
14
3.52:
-8,095
-41:
-931
(
151
3.85:
-8,037
-33:
-76(
4:
15
3,815
-8,0371 -35:
-80
4:
eP
13
3,052
-8,296
-44:
-1,011
(
Ict
10
2,225
-9,159
-591 -1,36
(
‘ov
7
1,47;
-10,570
-745 - 1,701
(
let
6
1,175 -11,679
-825 -1,88
(
2,21:
-62f
.verage
Vper m2
I
10
1s
-9,864
-831
-!
ns
en
8
lay
Co
-1.77:
.pr
11
,ug
ru
se
.
Ext Temp
Roof Wall Roof Elec Personnel Total
Total
Total
Total
Gains
Gains Cooling Losses Heating
Change Losses Losses Solar Solar Gains
Losses
Gain Gain
(-vd
(-ve)
kW
kW kW
kW
kW
kW
kW
kW
kW
kW
kW
Air
he
Fingleton
ot
&
- 1,421
-1:
Table A.3
EPA Export 25-07-2013:15:37:22
&
B
Fingleton
White
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
LINKS AND REFERENCES
http:iiwww.cer.iel
http://www.dcmnr.gov.ie/enerlzv/
http:l/www.sei.ie/
http:l/www.epa.iel
http:/lwww.esolar.cat.com/
http:lfwww.wartsila.com/
http://www.mz.siemens.com/en/fuelcells/
http://www.rolls-royce.com/
http://www.met.ie/
of Air Conditioning
System Design ISBN 07-010090-X
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Handbook
Aunclzment G Intel Sustainable Energy Shady
Page 42 of 43
EPA Export 25-07-2013:15:37:22
&
Fingleton
Intel Ireland
Sustainable Energy Report
Date: 05/06/03
CALCULATIONS
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
C
White
Attachment
G Intel Sustainable
Energy
Shrdy
Page 43 of 43
EPA Export 25-07-2013:15:37:22
EPA Export 25-07-2013:15:37:22
se
Co
n
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
nt
o
se
.
ru
he
ot
EPA Export 25-07-2013:15:37:22
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ns
en
Co
se
ru
he
ot
.