© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

TECH GROUP EUROPE DUBLIN

S.E.I. ENERGY MAP

WORKSHOP 4

Keith Henderson

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

Items to Cover

1. Total Energy Consumption2. Energy Survey and Metering3. Register of Opportunities*4. Project Charter* – Compressed

Air5. Programme Plan*Please note that there are documents linked to these sections

that must be downloaded. Please see resource box for these items.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

Total Energy Consumption

12 months up until 1st November 2006, Annual Electricity Bill – in the region of €1.2m

Increase of 31% for 2007

Forecasted Electricity Bill for 2007 (assuming same consumption as previous year) - in the

region of €1.6m

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without written permission of West Pharmaceutical Services.

Energy Survey and Metering

• Energy Survey carried out throughout the plant to identify areas of saving opportunity.

• High level metering installed to provide electricity split to Business Units.

• Hand held meter purchased for evaluation of individual items.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

Energy SurveyingPercentage Split of Facility Energy

IMM Business Unit 3, €49,459.20, 4%

IMM Development, €10,752.00, 1%

IMM Business Unit 2, €263,424.00, 19%

IMM Business Unit 1, €377,090.56, 28%

Process Chillers, €179,222.40, 13%

Material Dryers & Vacuum Units, €0.00, 0%

HVAC Chillers, €145,824.00, 11%

Air Handling Units, €163,511.04, 12%

Compressed Air , €90,316.80, 7%

Lighting , €71,755.13, 5%

Lighting

Compressed Air

Air Handling Units

HVAC Chillers

Process Chillers

Material Dryers & Vacuum Units

IMM Business Unit 1

IMM Business Unit 2

IMM Business Unit 3

IMM Development

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

High Level Metering

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without written permission of West Pharmaceutical Services.

Energy Split per Business Unit

• The Effect of the Price Increase

€0.00

€20,000.00

€40,000.00

€60,000.00

€80,000.00

€100,000.00

€120,000.00

Total BU 1 BU2 BU3 PD

November Cost at old price November Cost at new price

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without written permission of West Pharmaceutical Services.

Hand Held Metering

Examples of metering carried out so far :-

• Air compressor – Receiver Comparison

• AHU for clean room 1 – AHU 6 Shut Down

• Chillers – Old Tricool v new York Chiller

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without written permission of West Pharmaceutical Services.

Compressor Comparison Before and After Receiver Installation

Compressor Comparison Changing Receiver

0

20

40

60

80

100

120

Time Period

Pow

er (

kW

)

Before Receiver Ins tallation Average Before Receiver After Receiver Ins tallation Average After Receiver

Before receiver installation average of 93kW After receiver installation average of 83.09kW

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

Compressed Air – Effects of Larger Receiver Installation

• Before receiver installation – average kW of compressor of 93.19 kW

• After receiver installation – average kW of compressor of 83.09 kW

• Estimated savings due to receiver installation is approximately €9,000

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without written permission of West Pharmaceutical Services.

Clean Room 1 - Air Handling Unit 6 Survey

0.00

10.00

20.00

30.00

40.00

50.00

60.00

AHU6 kW

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without written permission of West Pharmaceutical Services.

Clean Room 1 – Air Handling Unit 6 Survey

• Air Handling Unit Average Energy – 14.68kW

• Approximate Annual cost to run AHU 6 - €14,000

• Weekend Shutdown Hours – 63 hours

• Estimated savings due to switching off AHU6 at weekends when not used €5,000 !!!

• Savings could be considerably higher as the AHU costs would rise during the summer months due to cooling load being increased.

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without written permission of West Pharmaceutical Services.

Chiller Comparison

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

Tricool (kW) York (kW)

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without written permission of West Pharmaceutical Services.

Chiller ComparisonAvailable

Time Time % Avg. kW Time % Avg. kW

Chiller On High Load 145.5 127.50 87.63% 36.98 29.00 19.93% 28.69

Chiller Off-Load 145.5 18.00 12.37% 0.00 116.50 80.07% 13.18

kWh per Chiller from Analysis

Average Unit Cost

Running Cost per Hour

Running Cost per Day

Running Cost per Week

Running Cost per Year (at present conditions)

€87.10 €43.75 €43.35

Note :- Readings were taken on different days at the same time of the day. Also, the outs ide temperatures were s imilar (approx. 10°C), and the machine loads were also s imilar. The savings would increase the warmer the weather is due to the increased

efficiency of the new chiller.

€609.70 €306.22 €303.47

€30,484.75 €15,311.12 €15,173.63

€0.112 €0.112

€3.629 €1.823 €1.81

Savings

32.403 16.275 16.128

Old Tricool Chiller NewYork Chiller

Tricool York

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Register of Opportunities

• Is placed in the folder P:\Energy along with other material relating to the energy saving projects. Register of Opportunities.xls

• Will be incorporated into the company’s overall Lean Policy.

• Will be viewable, but password protected for changes and co-ordinated by Keith Henderson.

• Ideal scenario is to carry out a savings validation, by first measuring the usage, then measuring after project to show savings. See previous Compressed Air example.

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without written permission of West Pharmaceutical Services.

Project Charter

• New standard form being created to add to QMS and Lean Charter Introduction.

• Project charter now produced for compressed air project. Energy Project Charter.doc

• Project charters will be used for all projects requiring capital funding.

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without written permission of West Pharmaceutical Services.

Projects Completed

• Metering installed at high level of distribution system to split business units.

• New Chiller installed for Business Unit 1 Process Chilled Water. Approx saving €15,000 per year

• Power factor correction improvements to avoid bill charges. Approx saving €10,000 per year!!!

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

Projects Ongoing• MIC Level increase• Complete survey of all equipment in the plant. • Occupancy Sensors for lighting in areas of irregular /

infrequent occupancy.• Compressed Air – New air receiver installed and pressure

reduction program to commence.• AHU Filters – New project started to find more efficient

filtration in air handling units.• Cooling Tower refurbished and awaiting installation of

replacement variable speed drive.• Clean Room 1 key-switch operation for AHU Shutdown

when not in use – wired to BMS, awaiting software change.

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without written permission of West Pharmaceutical Services.

Projects Planned

• Lighting load reduction throughout the plant. Lighting accounts for approx. 8% of our electricity costs. €96,000.

• Chilled water temperature assessment to determine optimum required temperature in each area.

• Envirostart units to fit to injection moulding machines.

• Investigation of cold water spray/evaporative humidification to replace steam humidifiers on AHU 7 and AHU 8.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

Programme Plan

• Programme Plan currently being drawn up as part of our company’s new lean manufacturing introduction.

• Separate budget to be allocated to the energy programme plan.

© 2005 by West Pharmaceutical Services, Lionville, PA. All rights reserved. This material is protected by copyright. No part of it may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise,

without written permission of West Pharmaceutical Services.

TECH GROUP EUROPE DUBLIN

S.E.I. ENERGY MAP

WORKSHOP 4

END

Keith Henderson