Syngenta utilities

Energy Management at Jealott’s HillOwen EverallSite Engineering and Facilities Manager

17th July 2014

Classification: Internal Use Only

Classification: PUBLIC

2

Introduction


• Jealott’s Hill Site• Jealott’s Hill Infrastructure Legacy• Maintenance Strategy• Energy Management

• Energy Metrics (Consumption and Cost)• Electricity Management• Gas Management

• Case Study on B100 Boiler System• Associated Benefits• Summary• Close

3

Jealott’s Hill International Research Centre, Brack nell

Classification: INTERNAL USE ONLY

4

The White House – the first laboratory built in by I CI in 1928


5

…the site has grown since then…

…the site was established in 1927 and there has been a farm here for centuries


6

Jealott’s Hill today

Jealott’s Hill site is 60 acres with a buildings footprint 65,000 m² comprising offices, labs, glasshouses, restaurant, gym, IT server building…

An international employee base of 850 staff involved in a range of science activities related to world agriculture


We have the largest glasshouse research complex in Europe at 4,000m2

7

…contemporary working environment…


8 Classification: INTERNAL USE ONLY

Jealott’s Hill Infrastructure Legacy

9


…too expensive to operate…

• Johnson Controls commissioned R&D Building Maintenance Benchmark Data

• Jealott’s Hill operating at 2½ times the cost of majority of our peers


10



…out of control…

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47

kVA

• Frequently throughout the summer of 2004 the site limit of 5MVA was being breached

• Led to a project being initiated to reinforce the capacity to 7.5MVA at a cost of £500k


5MVA electrical

capacity being breached

11



…out of control…

…over capitalised…

• Many cases where too much plant has been installed resulting in high maintenance cost

and poor efficiencies


12

SustainablePlant

SimpleProcess

SafePeople

Maintenance Strategy


13


Safe People • minimise maintenance routines (e.g. direct drives), • reduce operational parameters (i.e. temperatures, pressures),• eliminate plant

Simple Process(es) • waste• site operating procedures• out of hours call outs• control loops

Sustainable Plant • maximise value add at project stage (capital investment)• maximise service delivery opportunity (ability to control)• minimise intervention post installation (maintenance)• minimise impact on environment


Sustainable

Simple

Safe

14


Safe People • minimise maintenance routines (e.g. direct drives)• reduce operational parameters (i.e. temperatures, pressures)• eliminate plant

Simple Process(es) • Waste• Out of Hours Call Outs• Building Services Control

Sustainable Plant

• maximise value add at project stage (capital investment)• maximise service delivery opportunity (ability to control)• minimise intervention post installation (maintenance)• minimise impact on environment


Sustainable

Simple

Safe

15

Waste Management in 2004

• No recycling

• 38 waste streams identified

• Using 12 waste contractors

• Only 8% of site waste processed

• £1000 per week in maintenance

• £1000 per week in fuel

• 3 tonnes of fuel/tonne of waste burnt


Sustainable

Simple

Safe

16

Waste Management

● 2006

- Ceased on site incineration

- Total Waste Management Contract

- Recycling rate approximately 15%

Glasshouse soil recycling June 2009


Sustainable

Simple

Safe

17

Out of Hours Call Outs

0

200

400

600

800

1000

1200

2004 2013


Sustainable

Simple

Safe

18

Out of Hours Call Outs

0

200

400

600

800

1000

1200

2004 2013

90% reduction


Sustainable

Simple

Safe

19

Building Services Control


Sustainable

Simple

Safe

20

B103 40ºC Walk In Stability Cabinet

35

36

37

38

39

40

41

42

43

44

45

1

78

15

5

23

2

30

9

38

6

46

3

54

0

61

7

69

4

77

1

84

8

92

5

10

02

10

79

11

56

12

33

13

10

13

87

14

64

15

41

16

18

16

95

17

72

18

49

19

26

20

03

Control with proprietary

control system, wasting energy

and giving poor performance


Sustainable

Simple

Safe

21

35

36

37

38

39

40

41

42

43

44

451

79

15

7

23

5

31

3

39

1

46

9

54

7

62

5

70

3

78

1

85

9

93

7

10

15

10

93

11

71

12

49

13

27

14

05

14

83

15

61

16

39

17

17

17

95

18

73

19

51

20

29

21

07

21

85

22

63

23

41

24

19

24

97

25

75

26

53

27

31

28

09

28

87

29

65

30

43

31

21

31

99

32

77

33

55

34

33

35

11

35

89

36

67

37

45

38

23

39

01

B103 40ºC Walk In Stability Cabinet

Control with BMS giving

good control and matching

energy input to losses

Door being opened!


Sustainable

Simple

Safe

22


Safe People

• minimise maintenance routines (e.g. direct drives),

• reduce operational parameters (i.e. temperatures, pressures),

• eliminate plant

Simple Process(es)

• Waste

• Out of Hours Call Outs

• Building Services Control

Sustainable Plant

• minimise maintenance requirement (simple, safe, reliable)

• minimise impact on environment (efficient)

• maximise opportunity at project stage (specify what you want)


Sustainable

Simple

Safe

23

Gas and Electricity Consumption and Cost

kWhrs

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

35,000,000

40,000,000

45,000,000

Gas Electrcity

2004


24


kWhrs

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

35,000,000

40,000,000

45,000,000

Gas Electrcity

2004

2013


25


kWhrs

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

35,000,000

40,000,000

45,000,000

Gas Electrcity

2004

2013

£-

£500,000

£1,000,000

£1,500,000

£2,000,000

£2,500,000

£3,000,000

Gas Electricity

2004

£440

k £1,2

50k


26


kWhrs

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

35,000,000

40,000,000

45,000,000

Gas Electrcity

2004

2013

£-

£500,000

£1,000,000

£1,500,000

£2,000,000

£2,500,000

£3,000,000

Gas Electricity

2004

2013

£560

k

£1,8

20k


27


kWhrs

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

35,000,000

40,000,000

45,000,000

Gas Electrcity

2004

2013

£-

£500,000

£1,000,000

£1,500,000

£2,000,000

£2,500,000

£3,000,000

Gas Electricity

2004

2013

2013

£1,2

10k

£2,9

20k


28

Electricity


29

Average Hourly Data December (kWhrs)

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

2004


30

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant


31


● Electricity


- Install inverter driven motors for pumps


32

Inverter driven water distribution pump


33


● Electricity



- Demand led control strategies rather than time enabled strategies


34

Demand led Control Strategies rather than time enab led

Time

Time Enabled Control

Supply


35


Time


Supply


36


Time

Ove

rsup

ply


Supply


37


Time

Ove

rsup

ply


Time

Demand Enabled Control

Supply


38


Time

Ove

rsup

ply


Time

Demand Enabled Control

Supply


39


● Electricity




- Lighting control (internal & external) (PIR, Microwave, Lux, BMS)


40


● Electricity




- Lighting control (internal & external) (PIR, Microwave, Lux, BMS)

- Rationalise plant (air compressors, intermediate pumps,...)


41

Rationalise Air Compressors


42

Rationalise Air Compressors


43

Identify where pumps are not needed…


44

…and remove them…


45


● Electricity




- Lighting control (internal & external) (PIR, Microwave, Lux)


- LED Lighting


46

LED Lighting in corridor, office, breakout and labo ratory spaces


47


● Electricity






- LED Lighting

- Integrating plant onto the BMS


48

B170 Central Research Dispensary

Stable 24/7 operation

Providing an environment for 900,000 compounds


49

B170 Central Research Dispensary Cooling

• Two sources of cooling;

• Chilled water controlled by BMS


50

B170 Sample Store Chilled Water to AHU


51


• Two sources of cooling;


• 8 DX split systems stand alone, on 24/7 under own control


52

B170 Sample Store DX Split Systems


53



• 8 DX split systems stand alone, full 24/7 under own control

• Integrated the two cooling systems to work in harmony

under the control of the BMS

• Improved control of plant to prevent heating and cooling systems from fighting each other


54

B170 Sample Store DX controlled by BMS


55

B170 Average Weekly Electrical Consumption

0

5,000

10,000

15,000

20,000

25,000

2012 2013

44% saving (£50k pa)


56


● Electricity






- LED Lighting

- Integrating plant onto the BMS

- Preventing heating and cooling plant from fighting each other in Controlled Environment Rooms


57

B130 Controlled Environment Rooms


58

0

20

0

40

0

60

0

80

0

10

00

12

00

14

00

16

00

18

00

20

00

01-Jul

02-Jul

03-Jul

04-Jul

05-Jul

06-Jul

07-Jul

08-Jul

09-Jul

10-Jul

11-Jul

12-Jul

13-Jul

14-Jul

15-Jul

16-Jul

17-Jul

18-Jul

19-Jul

20-Jul

21-Jul

22-Jul

23-Jul

24-Jul

25-Jul

26-Jul

27-Jul

28-Jul

29-Jul

30-Jul

31-Jul

01-Aug

02-Aug

03-Aug

04-Aug

05-Aug

06-Aug

42

% sa

vin

g in

en

erg

y re

sultin

g in

£2

3k

pe

r an

nu

m

B130 D

aily Electrical C

onsumption P

re and Post C

E

Control M

odifications 2012Ene

rgy saving

Classification: P

UB

LIC

59

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

2004

2013



60

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

2004

2013



Energy saving

61 Classification: PUBLIC

Gas

62

Site Boilerhouses by Consumption (kWhrs)

Confidential: Internal use only

0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

B100 B23 B110 B167 B101 B170 B88 B161 B173

2004

32MW installed capacity


63



0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

B100 B23 B110 B167 B101 B170 B88 B161 B173

2004

2013

16MW installed capacity

Halved the boiler capacity


64



0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

B100 B23 B110 B167 B101 B170 B88 B161 B173

2004

2013

Case study


65

B100 Physical Sciences Laboratory 16,000m 2


approx. 300 fume cupboards

66

B100 Original Boiler Installation 10MW

Boi

ler

4

Boi

ler

3

Boi

ler

2

Boi

ler

1

• Single circuit

• Constant volume

• BMS enable only

• Temperature control on return of boilers

• Operating at 120ºC

T

Heating Pump


Controlling at 120ºC

120ºC 120ºC 120ºC120ºC

67

Original Boiler Installation 10MW


68

Heating Pumps

• Belt driven

• Fixed speed

• Difficult access

• Runs 24/7

• Costs >£30k pa to run


69

Heater Battery 3 Port Valve Arrangement

Heater Battery 3 Port Valve

Double Regulating Valve

• All of the boiler water flows all of the time (constant volume system)

Unused water flows through bypass


70

B100 Gas Consumption in 2004


71

B100 Hardware Modifications

Boi

ler 2

Boi

ler 1

P LOW

LO

SS

HE

AD

ER

T

Primary Heating Pump

Secondary Heating Pumpcontrolled via VSD and Pressure Sensor

Hydraulic freedom via Low Loss Header

Resited temperature control point

Demand side Supply side


82ºC

72

2 Boilers removed (5MW)


73

Modulating Burner Controls via BMS

• Firing rate set by BMS based on demand from the building

• Reduces the number of times a burner is fired thus improving efficiency


74

B100 Secondary Heating Pumps

• Direct drive

• Inverter speed control

• Variable duty

• Easy access

• Operating at 82°C

• Runs on demand


75

B100 Immersion Heaters for Domestic/Process Hot Wat er


76

Intermediate Heating Calorifier


77

Intermediate Heating Calorifier removed


78

Variable Air Volumes in selected Laboratories


79

Heater Battery 2 Port Valve Arrangement

Heater Battery 2 Port Valve

• Only boiler water that is required is supplied (variable volume system)

No wasted water


80

Software Control Strategies Employed

● Variable temperature control at boiler flow (compensated circuit for outside air temperature)


81

Compensated Boiler Flow Temperature Control

0

5

10

15

20

25

80 80 80 80 80 80 80 81 82 83 84 85 86 87 88 89 90 90 90 90 90

Out

side

Air

Tem

pera

ture

Boiler Flow Temperature


As outside temperature falls we increase boiler flow temperature

82



● Unoccupied Strategy

- Lab AHU controls ‘night temperature setback’ to provide fabric protection


83

Night Temperature Setback

0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Night Temperature Setback

time


Energy saving

84




- Lab AHU controls ‘night set back temperature’ to provide fabric protection

- lower fabric set point determined by dew point control


85

Dew Point Control for Unoccupied Time Zone

0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Lower night setback

temperature

where conditions allow

avoiding dew point

time


Additional

energy saving

86




- Lab AHU controls ‘night set back temperature’ to provide fabric protection

- lower fabric set point determined by dew point control

● Occupied Strategy; set point is based on ambient outside temp and is also influenced by lux level


87

Lux Control

0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Lower day temperature

when sun shines

time


Energy saving

88

B100 Gas Consumption after modifications 51% reduct ion


Energy saving

89

Normalised Gas Consumption (space and temperature)

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

35,000,000

40,000,000

2004 2006 2008 2010 2012 2014

69% reduction


90 Classification: PUBLIC

Associated Benefits £

91

Jealott’s Hill Water Consumption (Tonnes)

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

200,000

2004 2014

64% reduction


£

92

Building Maintenance Costs reduced 71%

£-

£500,000

£1,000,000

£1,500,000

£2,000,000

£2,500,000

£3,000,000

£3,500,000

£4,000,000

£4,500,000

£5,000,000

2004 2013

71% reduction


£

93

Summary

• A robust Engineering Maintenance Strategy will deliver

� reduced utility consumption as well as…

� reduced operational risk (safer)

� better building services control (simpler)

� reduced operational maintenance costs (sustainable)


94

Any questions?

Thank you


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