Genzyme Sustainability Programs 2012
March 19, 2012
Erik Familial Hypercholesterolemia USA
www.genzyme.com
|
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
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Genzyme History
•
Energy Program Structure
•
Program Performance
•
Sustainable Commissioning (SC) Concept
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Retroactive Commissioning
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Ongoing Monitoring
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Annual Energy Auditing
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Energy Modeling
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Ongoing and Retroactive Commissioning Research
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OCx/RCx Case study 1 – (177k s.f. research building)
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OCx/RCx Case study 2 – (290k s.f. office building)
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Linking Energy Management to Asset Care and Reliability
Genzyme Sustainability Programs
History
• Genzyme is a biotechnology company based in Cambridge
Massachusetts
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•
•
•
•
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 Programs
Energy and Sustainability Program Structure
Mission: To partner with sites to procure and use energy at Genzyme in
an efficient, cost effective, and environmentally responsible way
Market Intelligence
 Strategic Sourcing
 Leverage Scale

Eliminate Waste
 Benchmark Metrics
 Reduce Risk

Measure Carbon
Footprint
 Engage Employees

Supply
(Directed by
Brenda Henderson)
Demand
(Directed by
Steven Driver)
Greenhouse Gas
(Directed by
Jeff Holmes)
Competitive Pricing
 Reduced Energy Cost
 Commodity Quality

• Reduced Energy
• Increased Reliability
• Reduced Operating Cost
• Achieve GHG Target
• Environmental Leader
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
 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
7
Genzyme Sustainability Programs
How did we do it?
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Formed a focused team in 2007 (Supply, Demand, GHG)
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Obtained 1.9m in financing to implement ECM’s with a 1 year
or less return on investment
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Aggressively pursued and completed 79 energy projects
Conducted ASHRAE level 1 energy audits all major energy
consuming sites
Combined energy auditing, modeling, retroactive and ongoing
commissioning into one service
Genzyme Sustainability Programs
How did we do it?
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Allocated funding to sites for ECM engineering, controls,
reprogramming, and addressing functional issues
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Held weekly teleconferences with our sites to review
progress, schedule, budget, and M&V of ECM’s
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Measured savings through actual energy usage,
conservative engineering calculations, and metering
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Aggressively pursued utility rebates
Genzyme Sustainability Programs
International common theme ECM’s
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Lighting levels too high
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Air change rates beyond
EU classification requirements
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Humidity and temperature control
parameters (not required)
Lack of lighting sensors
Sequence of operations not optimized
for energy
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Unnecessary HVAC in mechanical
spaces
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Broken/out of calibration controls
Free cooling not being utilized
Strategic Demand Control
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Thermostatic dead band ranges
too narrow
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Simultaneous heating and cooling
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Lacking use of grey water
High purity water and steam
usages (steam trap failure)
Mechanical equipment upgrades
Less than ideal boiler efficiencies
High air filtration requirements
Sustainable Commissioning Concept
Combining energy auditing, RCx, OCx
• Annual energy auditing
(conduct operational interviews, functional testing, energy modeling)
• Continuous commissioning SM (OCx)
(artificial intelligence is used to collect fault data)
• Retroactive commissioning (RCx)
(collect generate fault data from observations)
Sustainable Commissioning Concept
Annual functional and operational auditing
The energy assessment team consists of 4 board certified energy
professionals trained in energy auditing and energy management with a
focus on retroactive commissioning.
Energy Audit Director:
Steven Driver, Ph.D, CEA, CEM
Certified Energy Auditor, Certified Energy Manager
Multi-Discipline Energy Auditor:
Jennifer Jones, CEA
Certified Energy Auditor
Mechanical Energy Auditor:
Jeffery Fong CEA, CEM
Certified Energy Auditor, Certified Energy Manager
Electrical Energy Auditor:
Tim Rossini CEA, CEM, LEED AP
Certified Energy Auditor, Certified Energy Manager
Sustainable Commissioning Concept
Annual functional and operational auditing
Request for Information
Conduct Assessment
Build Energy Model
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
Generate Report
Create final report, estimate costs for ECM’s, savings,
and ROI, IRR, NPV – use energy model
Present Findings
Present finding to site management in form of ppt
presentation
Conduct Workshop
Return to site to rank ECMS (ROI, quick, simple,
feasible
Track Implementation of ECMs
Add high priority ECM’s to international tracking
matrix, conduct weekly meetings
Re-Assess
Return to site for re-assessment (functional test
annually RCx). Implement OCx whenever feasible.
Sustainable Commissioning Concept
Functional and operational auditing
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In-field instrumentation used:
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Infrared thermograph
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Amp Probes
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Lighting level analysis
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Vane Annometer
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Combustion analysis
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Magnehelic gages
Vaneannometer
Infrared
thermograph
Magnehelic
Gauge
Amp Probe
Light Meter
Combustion
Analysis
Sustainable Commissioning Concept
Functional and operational auditing
Build an energy model and calibrate to existing energy bills to analyze
demand and understand where energy is being consumed. Identified
ECM’s are profiled and parametric runs completed using different
alternatives to understand financial impact on energy
Sustainable Commissioning Concept
Combining 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 Concept
Combining energy auditing, RCx, OCx
In 2007 there were still many unanswered questions around
commissioning:
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In a recent study of 60 commercial buildings conducted by the
Oregon Office of Energy, half suffered from control problems
such as malfunctioning equipment.
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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.
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Gordon (2007) claimed that using computer technology for energy
monitoring allows maintenance workers to be called only when
something requires repair.
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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 Concept
Two 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 Concept
32 common faults were universal throughout the 80 buildings
1 Discharge / Return temperature fault
2 Discharge / Exhaust pressure / static flow
3 Economizer / Outdoor Exhaust Damper
Fault
4 Simultaneous heating and cooling
5 Return / Space Air change rate under / over
6 Space temperature fault
7 Fan Cycling / Damper Oscillation
8 Air balancing / Leaking
9 Visual Thermostat in wrong location
10 Visual Deflection / Vibration /
Overheating/Binding
11 Relative Humidification Fault
12 Visual improper valve / damper position
13 Pump / Valve / Oscillation Cycling / Leak
bye
14 Water / Steam temperature
15 Water / Steam Pressure
16 Water / Steam flow
17 Water / Steam leaks
18 Pneumatic pressure (valve / damper)
19 Fan / Valve Signal Oscillation / Unstable
20 Meter calibration
21 Sensor / Switch / Signal calibration / Low voltage
22 Sensor / switch fault / Controller Flat line
23 Smoke / Hood / Air filter Alarms
24 Envelope leaks / Building Pressurization
25 Visual Observations (incorrect installation,
damage, drainage, missing equipment)
26 Equipment Accessibility Issues / Housekeeping
27 Equipment Performance / VFD
Control/Status/Fault
28 Runtime / Overridden in hand position
29 Engineering issue (over/undersized)
30 Incorrect labeling / Documentation Conflict
31 Sequence Optimization / Tuning / Programming
32 Field/BMS Issue (reversed or incorrect wiring)
Sustainable Commissioning Concept
Energy savings from ongoing and retroactive commissioning
Sustainable Commissioning Concept
Combining ongoing monitoring and RCx concurrently
(Case Study 1)
In 2011, RCx and RCx were employed concurrently in a LEED rated gold building
approximately 6 years old. Energy opportunities identified with corresponding fault
number from previous slide:
• Economizer malfunction (3)
• Scheduling of return fans (31)
• Discharge air temperature (1)
• VAV box turn-down ratios (27)
• CO2 sensor calibration (21)
• CW Valve leak bye (13)
• Simultaneous heating and cooling (4)
• Space temperature faults (6)
• Humidification (11)
• Occupancy Schedules (31)
Sustainable Commissioning Concept
Combining ongoing monitoring and RCx concurrently
(Case Study 1)
Financial results:
Description
ENE Controls
Ongoing Commissioning
Retroactive Commissioning
Rebates
Total
Invested Cost
$20,394
$60,400
$24,000
-$54,257
$50,537
Gas
$8,744
$32,000
Savings
Elect
$69,818
$45,500
Total
$78,562
$77,500
$156,062
Financial Analysis
Parameters
USD
2011 Items
Frequency
Antispated Cash Flow
half first year
Implementation cost
Net Cash Flows
one time
Cash flows for ECM IRR
Cash flows for program IRR
NPV (at 10.67%)
Payback (months)
IRR of program
$550,433
3.9
309%
2011
78,031
2012
2013
2014
2015
2016
0
0
0
0
0
(50,537)
27,494
0
156,062
0
156,062
0
156,062
0
156,062
0
156,062
(50,537)
(50,537)
156,062
156,062
156,062
156,062
156,062
156,062
156,062
156,062
156,062
156,062
Sustainable Commissioning Concept
Combining ongoing monitoring and RCx concurrently
(Case Study 1)
49 Science Center - additional issue identified through functional energy audit:
Clogged reheat coil: Fan deadheads at 4.25 hp while normal operation is 3.5 hp.
Energy Charge
Demand Charge
HPsaved :
0.750
HPsaved :
0.750
kW:
0.560
kW:
0.560
Utility Rate
($/kW*yr):
0.126
Demand Utility
Rate($/kW*mo):
19.720
Operating Hrs.:
8760.000
Operating
months.:
12.000
Operating
Savings ($/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 Concept
Ongoing monitoring
(Case Study 2)
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Identified 23 opportunities at Genzyme Center, Cambridge (LEED Platinum)
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$403,957 savings identified since OCx began in 2009, $259,137 implemented
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CO2 savings implemented: 803 Metric Tons
Sustainable Commissioning Concept
Ongoing monitoring
(Case Study 2)
One ECM was to widen thermostat dead bands for occupied times.
There was no reported adverse impact to employee comfort and the
result was $100,237 per year, 407 tons carbon!
Sustainable Commissioning Concept
Ongoing monitoring
(Case Study 2)
Sustainable Commissioning Concept
Ongoing Monitoring
Genzyme Sustainability Programs
Linking energy management to asset care and reliability
GHG Emissions
Reduction
Reduced Energy
Consumption
Increased
Reliability
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?
Idle/Minor stop
Reduced Rate
Moves the bar
Scrap/ Rework
Availability
Start up Loss
Efficiency
Lost Units
Set-up
Containing and Controlling Loss
Lost Speed
Breakdowns
Lost Time
Theoretical Max
Current Capacity
Performance
Quality
Everything we do must move
the line
Genzyme Sustainability Programs
Linking energy management to asset care and reliability
Changes in Vibration PF interval 1-9 months
Point where
Wear Debris in oil P-F
Quantitative PM P-F
failure starts
interval 1-6 months
Interval 5-8 weeks
to occur
IR Thermograph P-F
interval 3-12 weeks
P1
P2
P3
P = Potential Failure
Audible noise P-F
interval 1-4 weeks
P4
P5
P6
F = Failure
F
32
Genzyme Sustainability Programs
Linking energy management to asset care and reliability
Critical manufacturing air handler simultaneous H&C fault
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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
Ongoing
Monitoring
Industry
Benchmarking
Retroactive
Commissioning
Cost
Reliability
Quality
Energy
Auditing
Reliability
Monitoring
Energy
Modeling
Asset
Care
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
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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