Genzyme Sustainability Programs 2012

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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 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

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 MTCO
2

from 2007
-
09




Saved 6072 MTCO
2

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 Programs

How 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 Programs

How 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 Programs

International
c
ommon theme ECM’s



Lighting levels too high


Lack of lighting sensors


Sequence of operations not optimized
for energy


Air change rates beyond

EU 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 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


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 Concept

Functional and operational auditing




In
-
field instrumentation used:


Infrared thermograph


Amp Probes


Lighting level analysis


Vane Annometer


Combustion analysis


Magnehelic gages

Vaneannometer

Infrared
thermograph

Amp Probe

Light Meter

Magnehelic
Gauge

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:






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 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:


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



HP
sav ed

:

0.750

HP
sav ed

:

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)


Identified 23 opportunities at Genzyme Center, Cambridge (LEED Platinum)


$403,957 savings identified since OCx began in 2009, $259,137 implemented


CO
2
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

Increased

Reliability

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 Time

Lost Speed

Lost Units

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


Energy

Auditing


Energy

Modeling


Asset

Care


Reliability

Monitoring

Retroactive

Commissioning

Ongoing

Monitoring



Cost

Reliability

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