Case Studies

Client: Wilton Centre Laboratories – Redcar - Middlesbrough

 

Benefits:

• Energy savings = 3.4m kWhr/pa

• Energy cost savings =  £205,000

• Emissions reduction = 1,700 te CO2

• Simple pay back typically = 1. 3 >1.7 years

 

Facility: Large laboratory Facility spread over 5 blocks - originally designed as ICI’s R & D Facility

 

Issue: Old HVAC plant serving a very large number of face & bypass fume cupboards

Brief: Reduce energy demand without compromising on operator safety

 

Solution:

• Upgrade supply units with control & filtration upgrades

• Retrofit VAV to the existing fume cupboards

• Install pressure controllers to each laboratory

• Initiate fume cupboard diversity into each laboratory

• Strip out all the primary extract fans & upgrade secondary fans with VSD’s

• Installation of energy monitoring units to verify savings & act as MM&T capability

 

Conclusion: EECO2 – Phased upgrade over 3 years = carried out complete system redesign, scope & bid proposal on Clients behalf, laboratory user interphase & programming.  Provided Project Management for Contractors – delivered to budget, on time with 0 accidents or incidents

 

Site Energy Manager Comments:

We have just read the electricity meters in R Block for April, & I thought you might be interested to see the effect of the ventilation modifications which we have carried out. Basically, you can see that a monthly figure of around 120 MWhr has reduced to around 70 MWhr, which is a very significant reduction.

When we also compare total steam use for the whole Wilton Centre for 2009 with 2008, where we see a reduction of 9.5%, & some of this will be due to the similar work we did in T Block.

It is our intention to now carry out similar modifications in D, N & E Blocks.

 

Richard Short

Site Utilities Manager

 

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Client: GSK – Consumer Health Supply Division – Buenos Aires - Argentina

 

Benefits:

• Energy savings = 1.5m kWhr/pa

• Energy cost savings = £58,000

• Emissions reduction = 686 te CO2

• Simple pay back = 11 months

 

Facility: Effervescent Sachets Manufacturing Area – low relative humidity required

 

Issue: Very high energy demand driven by original HVAC design & unable to meet Product critical conditions during summer months

 

Brief: Reduce energy demand without compromising on product quality or Compliance

Solution:

 

Solution:

• Reduce existing air change rates

• Reduce existing fresh air volume

• Install new VSD’s to the supply air fans

• Replace the existing supply air diffusers to improve air distribution

• Re-commission & balance the complete manufacturing areas HVAC system

• Supported upgrade of BMS system, installation of VSD’s

• Maintenance upgrade of filtration & control valve replacement

• Completed product risk assessments, Engineering Change Control documentation & all required Regulatory documentation covering the changes

 

Conclusion: EECO2 supported HVAC design review, recommissioned HVAC system & supported BMS & HVAC upgrade also design of new supply air diffusers

 

Site Director commented:

The savings delivered during Phase 1 has exceeded our expectations & the quality Team have supported the risk based approach used to deliver the savings.  We now move on to Phase 2 upgrade which is much more demanding but the confidence & structure knowledge we gained during phase 1 we help us deliver our target for 2011

 

 

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Client: GSK – GMS Division – Quality Road & Jurong sites - Singapore

 

Benefits:

• Energy savings delivered  = 2.2m kWhr/pa

• Energy cost savings = S$347,000

• Emissions reduction = 985 te CO2

• Simple pay back = 1.3 years

• Further energy savings identified = 2.5m kWhr/pa

 

Facility: Pharma Manufacturing & laboratories

 

Issue: Very high energy demand driven by original HVAC design & layout

Brief: Reduce energy demand without compromising on Compliance or Laboratory safety

 

Solution:

• Reduce existing air change rates

• Reduce existing fresh air volume

• Improve plant operational maintenance

• Optimise BMS system

• Recommended upgrading laboratory fume cupboards to VAV

• Recommended upgrade & control of warehousing Facilities

 

Conclusion: EECO2 supported HVAC design review, project scoped out & managed local test & balance & BMS Contractors to complete project – project successfully completed also produced a prioritised Action Plan to implement further savings

 

 

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Client: GSK – Consumer Health Supply Division – Memphis – Tennessee

 

Actual Verified Benefits:

• Energy savings delivered = 1.95m kWhr/pa

• Energy cost savings = $135,000

• Emissions reduction = 917 te CO2

• Simple pay back = 1.5 years

• Capital cost avoidance from not replacing

Retained Sample Store HVAC = $35,000

 

Facility: CME Warehouse - temperature & humidity controlled storage of regulated product, also include the HVAC system in the Retained Sample Store (existing R22 plant obsolete)

 

Issue: Very high energy demand driven by original HVAC design & layout

Brief: Reduce energy demand without compromising on Compliance

 

Solution:

• Reduce existing air change rates

• Reduce existing fresh air volume

• Install 2 new VSD’s to the 100kw supply air fans

• Replace the existing supply air diffusers to improve air distribution

• Use existing warehouse HVAC system to serve Retained Sample Store

• Risk based approach to mitigate potential “out of condition” impact

 

Conclusion: EECO2 supported HVAC design review, project scoped out & local contractors bid to complete project – project let & successfully completed

 

Site Energy Manager Comments:

“This project was key for delivering the sites 2010 energy target.  It exemplifies how the proper air flow & fresh air can contribute significant energy savings.  This type of project will be replicated in the remaining areas of our Facility”

Alan Stewart – Site Energy Manager

 

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