Syngenta utilities

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

17th July 2014

Classification: Internal Use Only

Classification: PUBLIC

2

Introduction

Classification: PUBLIC

• 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

Classification: PUBLIC

5

…the site has grown since then…

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

Classification: PUBLIC

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

Classification: PUBLIC

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

7

…contemporary working environment…

Classification: PUBLIC

8 Classification: INTERNAL USE ONLY

Jealott’s Hill Infrastructure Legacy

9

Jealott’s Hill Infrastructure Legacy

…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

Classification: PUBLIC

10

Jealott’s Hill Infrastructure Legacy

…too expensive to operate…

…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

Classification: PUBLIC

5MVA electrical

capacity being breached

11

Jealott’s Hill Infrastructure Legacy

…too expensive to operate…

…out of control…

…over capitalised…

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

and poor efficiencies

Classification: PUBLIC

12

SustainablePlant

SimpleProcess

SafePeople

Maintenance Strategy

Classification: PUBLIC

13

Maintenance Strategy

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

Classification: PUBLIC

Sustainable

Simple

Safe

14

Maintenance Strategy

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

Classification: PUBLIC

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

Classification: PUBLIC

Sustainable

Simple

Safe

16

Waste Management

● 2006

- Ceased on site incineration

- Total Waste Management Contract

- Recycling rate approximately 15%

Glasshouse soil recycling June 2009

Classification: PUBLIC

Sustainable

Simple

Safe

17

Out of Hours Call Outs

0

200

400

600

800

1000

1200

2004 2013

Classification: PUBLIC

Sustainable

Simple

Safe

18

Out of Hours Call Outs

0

200

400

600

800

1000

1200

2004 2013

90% reduction

Classification: PUBLIC

Sustainable

Simple

Safe

19

Building Services Control

Classification: PUBLIC

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

Classification: PUBLIC

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!

Classification: PUBLIC

Sustainable

Simple

Safe

22

Maintenance Strategy

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)

Classification: PUBLIC

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

Classification: PUBLIC

24

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

2013

Classification: PUBLIC

25

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

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

Classification: PUBLIC

26

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

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

Classification: PUBLIC

27

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

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

Classification: PUBLIC

28

Electricity

Classification: PUBLIC

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

Classification: PUBLIC

30

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

Classification: PUBLIC

31

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

- Install inverter driven motors for pumps

Classification: PUBLIC

32

Inverter driven water distribution pump

Classification: PUBLIC

33

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

- Install inverter driven motors for pumps

- Demand led control strategies rather than time enabled strategies

Classification: PUBLIC

34

Demand led Control Strategies rather than time enab led

Time

Time Enabled Control

Supply

Classification: PUBLIC

35

Demand led Control Strategies rather than time enab led

Time

Time Enabled Control

Supply

Classification: PUBLIC

36

Demand led Control Strategies rather than time enab led

Time

Ove

rsup

ply

Time Enabled Control

Supply

Classification: PUBLIC

37

Demand led Control Strategies rather than time enab led

Time

Ove

rsup

ply

Time Enabled Control

Time

Demand Enabled Control

Supply

Classification: PUBLIC

38

Demand led Control Strategies rather than time enab led

Time

Ove

rsup

ply

Time Enabled Control

Time

Demand Enabled Control

Supply

Classification: PUBLIC

39

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

- Install inverter driven motors for pumps

- Demand led control strategies rather than time enabled strategies

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

Classification: PUBLIC

40

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

- Install inverter driven motors for pumps

- Demand led control strategies rather than time enabled strategies

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

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

Classification: PUBLIC

41

Rationalise Air Compressors

Classification: PUBLIC

42

Rationalise Air Compressors

Classification: PUBLIC

43

Identify where pumps are not needed…

Classification: PUBLIC

44

…and remove them…

Classification: PUBLIC

45

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

- Install inverter driven motors for pumps

- Demand led control strategies rather than time enabled strategies

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

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

- LED Lighting

Classification: PUBLIC

46

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

Classification: PUBLIC

47

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

- Install inverter driven motors for pumps

- Demand led control strategies rather than time enabled strategies

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

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

- LED Lighting

- Integrating plant onto the BMS

Classification: PUBLIC

48

B170 Central Research Dispensary

Stable 24/7 operation

Providing an environment for 900,000 compounds

Classification: PUBLIC

49

B170 Central Research Dispensary Cooling

• Two sources of cooling;

• Chilled water controlled by BMS

Classification: PUBLIC

50

B170 Sample Store Chilled Water to AHU

Classification: PUBLIC

51

B170 Central Research Dispensary Cooling

• Two sources of cooling;

• Chilled water controlled by BMS

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

Classification: PUBLIC

52

B170 Sample Store DX Split Systems

Classification: PUBLIC

53

B170 Central Research Dispensary Cooling

• Chilled water controlled by BMS

• 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

Classification: PUBLIC

54

B170 Sample Store DX controlled by BMS

Classification: PUBLIC

55

B170 Average Weekly Electrical Consumption

0

5,000

10,000

15,000

20,000

25,000

2012 2013

44% saving (£50k pa)

Classification: PUBLIC

56

Energy Management at Jealott’s Hill

● Electricity

- Review running times of plant

- Install inverter driven motors for pumps

- Demand led control strategies rather than time enabled strategies

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

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

- LED Lighting

- Integrating plant onto the BMS

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

Classification: PUBLIC

57

B130 Controlled Environment Rooms

Classification: PUBLIC

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

Average Hourly Data December (kWhrs)

Classification: PUBLIC

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

Average Hourly Data December (kWhrs)

Classification: PUBLIC

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

Classification: PUBLIC

63

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

2013

16MW installed capacity

Halved the boiler capacity

Classification: PUBLIC

64

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

2013

Case study

Classification: PUBLIC

65

B100 Physical Sciences Laboratory 16,000m 2

Classification: PUBLIC

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

Classification: PUBLIC

Controlling at 120ºC

120ºC 120ºC 120ºC120ºC

67

Original Boiler Installation 10MW

Classification: PUBLIC

68

Heating Pumps

• Belt driven

• Fixed speed

• Difficult access

• Runs 24/7

• Costs >£30k pa to run

Classification: PUBLIC

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

Classification: PUBLIC

70

B100 Gas Consumption in 2004

Classification: PUBLIC

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

Classification: PUBLIC

82ºC

72

2 Boilers removed (5MW)

Classification: PUBLIC

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

Classification: PUBLIC

74

B100 Secondary Heating Pumps

• Direct drive

• Inverter speed control

• Variable duty

• Easy access

• Operating at 82°C

• Runs on demand

Classification: PUBLIC

75

B100 Immersion Heaters for Domestic/Process Hot Wat er

Classification: PUBLIC

76

Intermediate Heating Calorifier

Classification: PUBLIC

77

Intermediate Heating Calorifier removed

Classification: PUBLIC

78

Variable Air Volumes in selected Laboratories

Classification: PUBLIC

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

Classification: PUBLIC

80

Software Control Strategies Employed

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

Classification: PUBLIC

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

Classification: PUBLIC

As outside temperature falls we increase boiler flow temperature

82

Software Control Strategies Employed

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

● Unoccupied Strategy

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

Classification: PUBLIC

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

Classification: PUBLIC

Energy saving

84

Software Control Strategies Employed

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

● Unoccupied Strategy

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

- lower fabric set point determined by dew point control

Classification: PUBLIC

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

Classification: PUBLIC

Additional

energy saving

86

Software Control Strategies Employed

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

● Unoccupied Strategy

- 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

Classification: PUBLIC

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

Classification: PUBLIC

Energy saving

88

B100 Gas Consumption after modifications 51% reduct ion

Classification: PUBLIC

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

Classification: PUBLIC

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

Classification: PUBLIC

£

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

Classification: PUBLIC

£

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)

Classification: PUBLIC

94

Any questions?

Thank you

Classification: PUBLIC