Dartford Electrical Energy Survey Report Rev F

8/12/2019 Dartford Electrical Energy Survey Report Rev F

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Customer Name: GlaxoSmithKline Services & ProjectsYour Ref: Our Ref: D1.00405Project Name: Electrical Energy Survey Page Number 1

Electrical EnergySurvey

GSKDartford facility

Name Position Signature DateProject led by: David Snow Senior Energy Consultant 25/7/08

Assisted by: Nick Ignadossian Power Consultant

Andy Turtle Motors & Drives specialist

Steve Gordon Energy Services TechnicalManager

Authorised for Issue: Kevin Jones Consultancy Solutions Manager


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Table of Contents

1 Executive Summary........................................................................................... 32 Summary of Options.......................................................................................... 4

2.1 Energy Saving Calculations ....................................................................... 63 Background ....................................................................................................... 94 Options............................................................................................................ 11

4.1 Tariffs, Billing & Consumption.................................................................. 114.2 Metering & Monitoring.............................................................................. 174.3 Motors...................................................................................................... 244.4 Lighting.................................................................................................... 304.5 Power Quality and Availability.................................................................. 404.6 Building Controls & Building Management Systems................................. 444.7 Voltage Reduction ................................................................................... 53

5 Appendices...................................................................................................... 54


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1 Executive Summary

This report details the findings of an electrical efficiency audit undertaken bySchneider Electric at GSK, Dartford, UK. The survey was undertaken between Apriland June 2008.

The annual electricity consumption for the site for the period April 2007 to March2008 was 41,670,734 kWh with an associate cost of 2,080,314.

Of the savings identified, 30,000 p.a. may be achieved with no capital expenditure.A saving of approximately 140,000 p.a. may be achieved from implementingmeasures with estimated CAPEX of 430,000 providing a Simple Payback (SPB) of3 years.

Implementation of all measures would save approximately 7% of the current utilityspend. This equates to approximately 3,040 MWh of electricity per year. Indirect

carbon dioxide savings related to this are estimated at 1,337 tonnes.

We would like to acknowledge the help and assistance given to us by Phil Broszek,Chris Couves, Phil Garland (Johnson Controls) and Allen Higgs (BAS) for providingus with essential information and assistance.


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2.1 Energy Saving Calculations

Assumptions made in the energy saving calculations are as follows:

2.1.1 Tariffs & billing

A reduction of the base load in off peak times is calculated using the followingassumptions:

Sum of all consumption for Year ending March 2008 for weekend days only =9,228,857kWh. Assuming that this represents off peak (although someweekends are peak, holiday periods are not included). Assume a 10%reduction in this off peak period is feasible through actions detailed in section4.1.5.

2.1.2 Monitoring & Targeting

Energy savings related to implementing a good monitoring & targeting system can

yield savings of at least 5% in buildings and 1% in production areas. This informationis obtained from the UK Carbon Trust Good Practice guide 112, Monitoring &Targeting in large companies. Several case studies within this guide have indicatedthat the typical savings were between 1.8% and 14% across a number of differentindustries.

2.1.3 Motors & Drives

Variable Speed DrivesThe following simple calculation is used for variable speed drives:

A Assume current power loading (75%)B Assume current utilisation factor (hours used)C Assume % flow reduction after VSD fittedD Obtain Motor rating (kW)

Energy saving = (A*B*D) (B*D*(C^3))Ie Power Saving = flow saving^3

High Efficiency Motor replacement

Where data has been available and recorded, full load efficiencies have beencalculated and are compared to the EFF rating scheme.

Full load efficiencies have been calculated, where data was available, as follows:

Efficiency % = Rated power x 100Input power

and Input Power = 3 x voltage x full load current x power factor

Where the data is incomplete, the EFF2/EFF3 boundary efficiency figure has beenused, in line with CEMEP guidance.


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Where the measured full load current is available, the spot percentage loading of themotor is calculated. Otherwise, 75% has been assumed.

Full load efficiencies have been used. Modern high efficiency motors tend to have aflatter load/efficiency curve than conventional motors, so the efficiency gain may wellbe better than assumed at less than full load, as most motors will be.

The potential annual saving has been calculated as follows:

Saving = Input power x loading % x annual hours x efficiency delta x 4.58p

Motor cost is based upon Brook Crompton price list, less 45%, plus 50% forinstallation. Costs for a flange mounted model have been assumed as the moreexpensive. Prices are based on safe area classification only.

2.1.4 Lighting

All lighting details are included in Appendix 1. Assumptions on run hours have beenderived through occupancy statistics and evidence from the site surveys. In areas ofhigh occupancy, it is assumed that the lighting hours can be reduced by 10%,

otherwise light hours can be reduced by 30% through automatic controls. Wherelights are switched off, it is assumed that the area follows good practice and only10% savings on hours used is possible.

Only areas where the installed lighting exceeds kW are considered for automaticcontrols.

2.1.5 BMS

Best practice case studies indicate that around 18% savings can be achievedthrough implementing a good BMS system where none previously exists. Thefollowing yardsticks (based on UK government statistics) can be used for estimating

heating and cooling usage:Heating& HotWater Cooling

Fans,Pumps,Controls

Goodpractice 97 14 30

Air-conditioned,standard offices

TypicalkWh/m2

p.a. 178 31 60

Goodpractice 107 21 36

Air-conditioned,prestige offices

TypicalkWh/m2

p.a. 201 41 67

Good

practice 220 0 20

GeneralManufacturing

IndustrialBuilding Typical

kWh/m2p.a. 320 0 30

For the calculations, it is assumed that the areas with BMS installed are not runningto the optimum efficiency, and are only gaining half of the savings, then energysavings will be around 9% of the buildings concerned. It is also assumed that thebuildings fall into the typical category of the above matrix.


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2.1.6 Conclusion

The cost and hence ROI of all measures take no account of depreciated assetvalues. If some of the asset value can be written down, then the return oninvestment figures would improve accordingly.

All the assumptions above used in the calculations need to be validated throughfurther investigation and adjustments made accordingly.


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3 Background

GSK Dartford is situated 1 mile due north of Dartford in Kent and covers an area ofapproximately 35 acres.

The Dartford site has been home to pharmaceutical manufacturing since 1889 whenthe Wellcome Foundation officially opened on 3 July.

Until a few years ago, the site was home to a large secondary manufacturing facilityand a small R&D facility (chemical development), as well as the existing primarymanufacturing facilities.

In January 2000 Dartford received the go-ahead for a 23 million investment for anew valaciclovir facility on the North Site, and in January 2003, a proposal wasannounced to cease primary manufacturing on the East - and older -part of theDartford site by the end of 2006. Primary manufacturing at Dartford was to befocused on the North site.

Dartford is responsible for manufacturing around 12 active ingredients for customers

around the world and is also a 'new product introduction' site, with a sustained recordof helping to bring new products to the market.

The site has received significant investment during recent years to build new state-of-the-art manufacturing facilities, improve and expand existing ones, as well as a newstaff restaurant, a Conference Centre and a new Site Reception and Securitybuilding.

The site now comprises of office accommodation, laboratories, packaging areas,warehousing and clean room processes. There is also an energy centre (buildings241 and 227) which houses a gas turbine and steam boilers although there are plans


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to decommission these buildings and build new facilities in the North West corner ofthe site.

There are approximately 600 GSK personnel and a further 400 contracted personnelworking on the site with a 2 shift pattern in the process areas. The processes are run24 hours a day, 365 days per year.

It is understood that the majority of the buildings in the South East section of the sitewill be vacated in due course, and operations will move to the main part of the site.This will include the following buildings:

Building 241 Combined heat and power plant

Building 227 BoilerhouseBuilding 225 General Offices

Therefore, only opportunities with short paybacks were considered in these areas.


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4 Options

4.1 Tariffs, Billing & Consumption

4.1.1 Supplier Tariff

The site electricity consumption has been calculated from the energy bills providedby RWE NPower. The electricity tariff is currently based on a seasonal time of daytariff with an availability charge on an agreed supply capacity of 15,000 kVA whichequates to 4,755 per month. It is understood that this tariff is an annual contract,renewable each October. Details of this tariff are as follows:

There are no charges relating to maximum demand (MD), although the MD should bearound 80% of the available capacity so that there is capacity for unexpected peaks,but there are no unnecessary availability charges. However, this is not the case asillustrated in the following chart:

MD v SC

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

Jan-

06

Feb-

06

Mar-

06

Apr-

06

May-

06

Jun-

06

Jul-

06

Aug-

06

Sep-

06

Oct-

06

Nov-

06

Dec-

06

Jan-

07

Feb-

07

Mar-

07

Apr-

07

May-

07

Jun-

07

Jul-

07

Aug-

07

Sep-

07

Oct-

07

Nov-

07

Dec-

07

Jan-

08

Feb-

08

Month

MD (kW)

SC (kVA)


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It is quite apparent that the supply capacity is far too high, and that around 8,000 kVAwould be adequate. This will need to be negotiated with RWE NPower, but if this canbe reduced, charges for 7,000 kVA capacity can be saved. This will equate to26,628 per annum.

The site profile for week commencing 4/6/07, which represents the daily profile withthe highest demand (Monday 7thJune) is as follows:

Week - kW profile

0

1000

2000

3000

4000

5000

6000

7000

01:00

03:00

05:00

07:00

09:00

11:00

13:00

15:00

17:00

19:00

21:00

23:00

Mon

Tue

Wed

Thu

Fri

Sat

Sun

This slightly higher consumption will most likely be attributed to the need for comfortcooling as the weather was quite hot at this time. The peak at the beginning ofThursday is a data anomaly and should be ignored.

Total consumption for the year April 2007 to March 2008 was 41,670,734 kWh withan associated cost of 2,080,314 inclusive of CCL (Climate change levy). The costtakes into account a flexible purchasing reconciliation which resulted in a credit to thesite of just over 258k for this period. There is a CCL agreement whereby 80% of theconsumption is exempt from the charge due to the intensive processes which GSK

claims. However, an action plan with targets needs to be adhered to for theexemption to be given. If these targets are not met, there is a risk of losing theexemption which would cost the site approximately 147k per annum.

Triad notices

At the end of the winter season (November 1st to February 28th), National Grididentifies the three half-hour periods of highest consumption of electricity, subject to aseparation of at least 10 calendar days. These three periods are called Triads. Thus,the half-hour in which national demand was highest is the first Triad; the secondhighest half-hour, excluding a period of 21 days centred on the first Triad, is thesecond Triad; and the third highest half-hour, excluding two periods of 21 days

centred on the first and second Triads, is the third Triad. Historically, Triads alwaysoccur on Mondays to Thursdays between 16:30 and 18:00 hours, and not close toChristmas (which is a period of relatively low consumption).

The site receives Triad warnings each year, and the site has to load shed to avoidpaying big penalties on the three highest periods, which are unknown until the end ofthe season. It is not effective to load shed for all of the triad warnings and it iscommon for end users to be penalised for the Triads. The penalties come in the formof TUOS charges (Transmission Use of System) and a charge of 22.16 per kW ofdemand during the Triad period is chargeable for the year. In 2007, the kW chargewas 1852.8kW which resulted in a monthly charge of 3,422.18.


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The load during the three Triad warnings were as follows:

20/12/06 17:30 5,340 kW23/1/07 17:30 100 kW8/2/07 18:00 80 kW

The average of these three loads, multiplied by the network operators lossadjustment factor, results in the penalty incurred for the following year. The first Triadwas missed and the site continued to run as normal. However, the second two

warnings were adhered to and standby generation was turned on which reduced theimported electricity consumption considerably. The charge in 2006 was 3390kW, but2008 has resulted in a high charge as two of these warnings were not observed:

26/11/07: 5040kW17/12/07: 260 kW3/1/08: 5220kW

In March each year, the National Grid publishes the three highest maximum demand(MD) readings that have occurred between November in the previous year andFebruary in the current year. The invoices therefore include a triad reconciliationfigure following this announcement. This figure will reconcile the difference betweenthe annual transmission charges and National Grids final triad charge. In 2007, thisfigure equated to a credit of 24,824.13. However, in 2008, the reconciliation figurehas resulted in a debit of 40,622.84 as only one warning was observed.

4.1.2 Forward electricity prices

The following table provides historical and forward contract prices for electricity in theUK market:

Electricity Month ahead prices

0

20

40

60

80

100

120

Oct

-05

Jan-06

Apr-0

6

Jul-0

6

Oct

-06

Jan-07

Apr-07

Jul-0

7

Oct

-07

Jan-08

Apr-0

8

Jul-0

8

Oct

-08

/MWh Average prices

Max prices

Min prices

The prices here are based on month ahead quotations, with the data collected on a

daily basis for the proceeding four months. The maximum and minimum prices showhow the months prices vary during the proceeding four months. For example, pricesfor July 08 were analysed from March to June and varied from 56 /MWh to87/MWh. This indicates the volatility of the market whereas the previous summerwas a lot less volatile.

As expected, the following chart illustrates that when the market is dropping, it is bestto buy late, and when the market is rising, it is best to buy as early as possible:


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Time to buy

0

20

40

60

80

100

120

05/08/2005

05/10/2005

05/12/2005

05/02/2006

05/04/2006

05/06/2006

05/08/2006

05/10/2006

05/12/2006

05/02/2007

05/04/2007

05/06/2007

05/08/2007

05/10/2007

05/12/2007

05/02/2008

05/04/2008

05/06/2008

Date of quote

/MWh

Oct-05

Nov-05

Dec-05

Jan-06

Feb-06

Mar-06

Apr-06

May-06

Jun-06

Jul-06

Aug-06

Sep-06

Oct-06

Nov-06

Dec-06

Jan-07

Feb-07

Mar-07

Apr-07

May-07

Jun-07

Jul-07

Aug-07

Sep-07

Oct-07

Nov-07

Dec-07

Jan-08

Feb-08

Mar-08

Apr-08May-08

Jun-08

Jul-08

Aug-08

Sep-08

Oct-08

Nov-08

Early indications for the winter are that the prices will be a lot higher, with the trendfor the last few months seeing the electricity price increasing at an alarming rate.

Using the current STOD tariff, average unit prices are as follows:

Rate Unit price ( perMWh)

% of total consumption

1 34.96 28.5%2 43.57 22.1%3 50.03 47.2%4 123.39 2.1%

The average price across the year ending March 2008 equates to 45.80 per MWh.Average best month ahead prices for the same period are 30.20 per MWh, up to42.43 for the worse prices. However, this contract rate is from October 07 toOctober 08. Best and worse average electric prices for this period equates to 50.50per MWh and 71.50 per MWH respectively. Therefore, the current unit prices aregood for this climate, but a price hike in October must be expected.

4.1.3 Billing procedures

The bills are currently received by the accounts payable department in Mitcheldean,Gloucestershire where they authorise them for payment and subsequently pay them.The engineering team at Dartford later receive the bills which they enter onto aspreadsheet and the hardcopies are then filed. The spreadsheet is primarily used forinternal meetings.


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As there is no procedure for reconciling the bills against half hourly data, it isrecommended that a more robust billing monitoring system is introduced asdiscussed in section 4.2.

4.1.4 Consumption profile

The consumption profile for the site is extremely flat, with no peaks and troughsthrough the day, days of weeks or even weeks in the year. This is illustrated by thefollowing profile, which is for week commencing 24/12/07, (Christmas):

Week - kW profile

0

1000

2000

3000

4000

5000

6000

00:00

02:00

04:00

06:00

08:00

10:00

12:00

14:00

16:00

18:00

20:00

22:00

Mon

Tue

Wed

Thu

Fri

Sat

Sun

The daily consumption profile for the year ending 31stMarch 2008 is as follows:

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

01/04/2007

15/04/2007

29/04/2007

13/05/2007

27/05/2007

10/06/2007

24/06/2007

08/07/2007

22/07/2007

05/08/2007

19/08/2007

02/09/2007

16/09/2007

30/09/2007

14/10/2007

28/10/2007

11/11/2007

25/11/2007

09/12/2007

23/12/2007

06/01/2008

20/01/2008

03/02/2008

17/02/2008

02/03/2008

16/03/2008

30/03/2008

TotalDailykWh

Other than a couple of instances, it is illustrated that the profile is fairly flat on a dailybasis which indicates that the processes run constantly. The drops in consumptionare due to the following:

Week commencing 17thDecember was a Triad period which was observed. Itis understood that the Gas turbine was running for a few days following thisperiod.

Monday 23rdApril had a small dip due to a production shutdown


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There is a significant dip in September, with the following profile on weekcommencing 17thSeptember 2007 being more than 20% lower than normal,with a weekly consumption of 638,700kWh. The Wednesday had a significantdrop with a maximum demand of less than 3,000kW.

It is understood that this weeks profile is lower than normal because there was ashutdown of the chilled water from building 449. As all the production areas rely uponthe chilled water, it would also mean that the production was shut down during thisperiod. This would explain the dip in consumption, but it is quite alarming that with noproduction on site, the base load is still around 60% of peak consumption.

4.1.5 Tariffs, Billing and Consumption Recommendations

It is recommended that:a) The supply capacity is reviewed and reduced to 7,000kVAb) It is recommended that activity is reviewed during periods of shutdown asthe base load appears excessive. The likely causes are as follows:

Primary Processes - Heat elements, Cooling elements, agitators and

compressed air provision when the process is not running. Secondary Processes Conveyors, packing machines. Heating, Ventilation and Air Conditioning (HVAC) Extract fans

especially may be left on in areas where it is not required. Lighting Lighting may be left on when areas are unoccupied.

A reduction of 10% in periods of inactivity is likely to result in an energy savingof 185 MWh p.a. (Total weekend usage equates to 9,228MWh, possible shutdowns estimated at every fifth weekend).

Savings related to the above equate to 38,891 with no additional capital costs.

It is also recommended that further investigation is undertaken to ascertainwhether the tariff structure fits correctly. There may be opportunities to buymonth ahead, or negotiate an increase in reactive power charge and a smallerunit rate. An increase in reactive power charge will benefit the site should itimplement the recommendations discussed in section 4.7.

Week - kW profile

0

1000

2000

3000

4000

5000

01:00

03:00

05:00

07:00

09:00

11:00

13:00

15:00

17:00

19:00

21:00

23:00

Mon

TueWed

Thu

Fri

Sat

Sun


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4.2 Metering & Monitoring

To control energy consumption and costs, regular and reliable records of energyusage should be maintained. These records will help to identify changes in energycosts and consumption. The simplest form of Monitoring and Targeting is torecord monthly energy usage which can be monitored and graphed on a computerspreadsheet or a specialised computer based system. This information can beobtained from invoices or by reading the meters.

Continuous assessment of consumption is required so that both the plant andcontrols continue to operate as intended, and to also ensure that the occupantsbehaviour continues to operate a good housekeeping policy. Energy savings canbe short lived, if the initial impetus is allowed to decrease.

A monitoring and targeting system should:-

Record energy consumption and any other factors that affect energy use(weather, occupancy, etc.)

Compare the energy use to previous years, or to yardsticks representing typical

or target energy performance Alert sudden changes in energy use patterns Provide regular summary reports.

Provide the relevant cost centers with their individual energy costs.

The system at GSK Dartford involves the monitoring of utility bills only, withcomparisons to production. This includes year on year performances with kg v kWh,cumulative sum charts and comparisons to degree days. This is good practice, butonly with increasing the number of data streams will the full benefits of monitoringand targeting be realised.

4.2.1 Metering

The initial method of increasing data streams will be through the introduction ofautomatic metering. Data will be collected from a number of meters across the siteevery half hour, and accurate profiles of consumption will be produced for all areas.This data can then be analysed against further production figures and othervariables. It is understood that many of the new meters have been purchased but notyet installed due to no available shutdown periods.

In section 4.5 of this report (power quality and availability), the electrical single linediagram is provided. This is useful as reference for the metering strategy. Thefollowing table details the existing metering system and includes the following metertypes:

E ElectricG GasW WaterS SteamA AirV Virtual (Consumption is calculated from aggregating actual meters)


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Ring MainFeeder Building No / Area

Metertype Meter Description

RMF1 241 CHP / Switchroom E Main Meter

RMF 10 442 132kV Sub E Main Meter

449 Water Resources E Transformer 1

449 Water Resources E Transformer 2

449 Water Resources E Condensor Water449 Water Resources E Cooling Water

449 Water Resources E Primary cooled water

449 Water Resources E Secondary Cooled water

449 Water Resources A

436 Gas EMC Incinerator G

436 Elec EMC Incinerator E

436 Steam EMC Incinerator S output

436 11kV sub E Transformer 1

436 11kV sub E Transformer 2


400 Production E Switchfuse N

400 Production E Switchfuse M

400 Production S

401 Production E Transformer 1 B422

401 Production E Switchfuse V

401 Production E Switchfuse U

401 Production S

403 Warehouse E



404 Production S

427 Technical development E Transformer 1

427 Technical development S


RMF2 241 CHP / Switchroom E Main Meter

225 Offices E

225 Offices S

227 Boiler House E Supply 1

227 Boiler House E Supply 2

227 Boiler House E Water Treatment

227 Boiler House VS Boiler 1



227 Boiler House W Feedwater boiler 1



227 Boiler House G

227 Boiler House V Boiler 1 - 3 Thermal efficiency

RMF3 241 CHP / Switchroom E

241 CHP / Switchroom S From boiler 4241 CHP / Switchroom W FW to boiler 4

241 CHP / Switchroom W FW Flash vessel

241 CHP / Switchroom E Transformer 1

241 CHP / Switchroom E Transformer 2

241 CHP / Switchroom G Comp 1

241 CHP / Switchroom G Comp 2

241 CHP / Switchroom V Thermal efficiency

241 CHP / Switchroom V Elec Efficiency

241 CHP / Switchroom V Combined efficiency

241 CHP / Switchroom VE Elec output

RMF 4 241 CHP / Switchroom E

RMF 5 241 CHP / Switchroom E


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There are multiple meters monitored in the utilities plant areas (Boilerhouse, CHP,Water services and Incinerators) and single meters at most of the buildings. Thefollowing buildings have no electricity meters at all:

Building 405 - ProductionBuilding 407 Grinding & Blending Unit

Building 417 Site ReceptionBuilding 418 Changing facilitiesBuilding 423 GatehouseArea 444 Contractors CompoundBuilding 445 OfficesBuilding 468 - Restaurant

Metering strategies recommended by the DETR, and now incorporated into Part LBuilding Regulations, concludes that 90% of the incoming energy into a site must beaccounted for. The guide stipulates the requirements as follows:

Reasonable provision would be to enable at least 90% of the estimated annual energyconsumption of each fuel to be accounted for. Allocation of energy consumption to the variousend uses can be achieved using the following techniques:- direct metering- measuring the run-hours of a piece of equipment that operates at a constant known load- estimating the energy consumption, e.g. from metered water consumption for hot waterservices (HWS), the known water supply and delivery temperatures, and the known efficiencyof the water heater- estimating consumption by difference, e.g. by measuring total gas consumption andestimating the gas used for catering by deducting the measured gas consumption for heatingand hot water- estimating non-constant small power loads using the procedure outlined in chapter 11 ofCIBSE Guide F: Energy efficiency in buildings(5).

Reasonable provision of meters would be to install meters in every building greater than 500m2 gross floor area (including separate buildings on multibuilding sites). This would include:- individual meters to directly measure total electricity and gas consumed within the building- a heat meter capable of directly measuring the total heating and/or cooling energy suppliedto the building by a district heating or cooling scheme.

Reasonable provision of sub-metering would be to provide additional meters such that thefollowing consumptions can be directly measured or reliably estimated (see above):

- Electricity and gas provided to each separately tenanted area that is greater than 500 m2- energy consumed by plant items with input powers greater or equal to that shown in Table13 of Approved Document L2 (ADL2) (reproduced here below)- any heating or cooling supplied to separately tenanted spaces; for larger tenancies, i.e.those with floor areas greater than 2500 m2, direct metering of the heating and cooling maybe appropriate, but for smaller tenanted areas, the heating and cooling end uses can beapportioned on an area basis.- any process load that is to be discounted from the building's energy consumption whencomparing measured consumption against published benchmarks


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Plant Item Rated powerinput (kW)

Boiler installations comprising one or more boilers or CHP plant feeding acommon distribution circuit

50

Chiller installations comprising one or more chiller units feeding acommon distribution circuit

20

Electric Humidifiers 10Motor control centres providing power to fans and pumps 10Final electrical distribution boards 50

These regulations only apply to new buildings and existing buildings when they areextended, and is not retrospective. However, it is good practice to follow theseguidelines, as further analysis will be beneficial (see section 4.2.2). GSK motormanagement policy stipulates that new motors above 30kW need to have metersinstalled, not the 10kW as Part L regulations suggest. In the instance of heavymanufacturing, the regulations are not always practical, and careful consideration asto the level of metering should be undertaken.

The following table can be used to ascertain the metering requirement:

STEPS 1-6WORKSHEET

Start by identifying the largest three or four end uses that can be metered easily; then iterate until at least 905of each incoming energy is metered.

STEP 1 Total annual fuel consumption (estimates) kWh / yrElectricity Gas. Water

STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

FuelType

Main enduses

EstimatedConsumption(kWh/yr)

Enduse/area/system/circuit tobemeasured

Identifyanyexistingmeters

Step 4.1

Measurementmethod

Step 4.2

Metercode

Step4.3

Metertype

Step4.4

Calculation Estimatedenergyconsumptionthroughmeter (kWh

/ yr)

Ismeteredwithin90% ofincoming?Yes / No

If no goback tostep 3

ELECT. Incoming

1stiteration - Electricity

Lighting

Cooling

CompressedAir

Processes

Is this 90% of incoming electricity?

2nd

Iteration Electricity (additional metering)

Is this 90% of incoming electricity?

GAS. Incoming

1stiteration - Gas

SpaceHeating

DHW

Catering

It is therefore recommended that one of these worksheets is filled initially for thelarger buildings to ensure that 90% of the buildings end use is monitored. This mayinvolve examining the distribution boards and identifying existing current transformers(cts) for the installation of a meter.

It is also recommended that a worksheet is then filled out for the entire site, so that90% of buildings are monitored.


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4.2.2 Data Capture

Data is currently collected through the Honeywell Scada system, where meters areconnected to local control systems and are networked back to the main Scadaoutstations. Every hour the consumption is aggregated and logged, so the resulting

consumption is in an hourly format. On a daily basis, a text file is uploaded to a standalone Montage software system. The software system is only accessed by PhilBroszek where specific reports are generated and issued in PDF format via email.The reports for Montage are only monthly as the variables that the consumption iscompared to is in monthly format (Degree days / production figures).

As previously mentioned, the more data collected, the better the output from the M&Tsystem. An ideal system would be collecting the consumption information in realtime, and compared to hourly or half hourly variables. The digital meters shouldcommunicate through a network protocol and data should be collected as inaccordance with standard robust data capture techniques (See Appendix 3):

4.2.3 Monitoring & Targeting

By analysing meter data, it can easily be compared to a variable such as productionor external temperatures. The following chart illustrates how this analysis can beundertaken using a regression analysis.

By plotting electricity v production, a linear trend line can be drawn. Equations in theformat of y=mx+c are derived, y being electricity consumption, x being the productionvariable, m being the gradient of the line and c being the constant or base load that isconsumed when there is no production. This equation becomes the target and canbe further analysed as a CUSUM (Cumulative Sum) graph:

Electrici ty vs Production

y = 558.08x + 124481

R2 = 0.9146

y = 566.78x + 31475

R2 = 0.9706

0

500000

1000000

1500000

2000000

2500000

3000000

3500000

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

P r o d u c t io n ( p o t s )

EleckWh


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This analysis subtracts actual use from the predicted use (y=mx+c). The difference isthen added together each time the analysis is undertaken. On target would bestraight along the X axes, behind target would be below the axis and ahead of targetwould be above the target. Exception reports can then be created when the actualconsumption deviates away from its target by an agreed tolerance.

By producing analysis in half hourly format by using real time analysis as detailedearlier, target daily profiles can be created and exceptions can be created as follows:

It is also recommended that the following charts can be used: Building League Tables (kWh / Production or Occupancy) Year on Year consumption profiles Year on year normalised consumption profiles (corrected for production/weather

etc) Energy consumption v target

It is essential that a flexible system is used that supports tailored report templates,ad-hoc report creation, 3rdparty data import (ex: ERP systems, BMS systems, PowerManagement systems, weather feeds), and user specific content display. Easy-to-use Administration, Data Quality, and Data Management tools will help companiesmaintain and grow their monitoring & targeting system. An example of this is includedin Appendix 6.


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4.2.4 Recommendations

Energy saving opportunities are as follows:-

a) It is recommended that a full metering audit is undertaken and new metersinstalled to ensure that 90% of the end use consumption is monitored on a halfhourly basis.

b) It is essential that a new software solution is implemented which can be flexibleand functional.

c) It is recommended that all contractors, who are cross-charged for their energyusage, should have sub-meters installed. This information should be passed onto the accounts department for cross-charging purposes, ensuring that standingcharges are taken into account within the calculations.

If possible, GSK should assess its existing staff structure and identify a part-timeoperator to be solely responsible for collecting and monitoring energy consumption

as well as utility invoice validation. Key personnel should be identified, and a reportstructure agreed whereby weekly/monthly reports on current performance aredistributed for use with the energy awareness program. Full procedures on theoperation of the M&T system should be kept, so that sufficient training can be givenshould there be any staffing restructures.

Energy savings related to implementing a good monitoring & targeting system canyield savings of at least 5% in buildings and 1% in production areas. It is estimatedthat this will equate to 1,309,000 kWh or 60,000. The implementation cost for thehardware of a system like this would be around 70,000 with software and trainingcosts around 50,000.


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4.3 Motors

4.3.1 Introduction

GSKs objectives are to reduce energy consumption in the operation of their electricalsystems, whilst maintaining safe and reliable power supplies. Recognising the largeproportion of total electrical energy which is consumed by motors, GSK are putting ahigh priority ensuring efficient use of motors. GSKs Motor Management Policy setsout the expectation of the sites and this audit addresses the requirement toproactively survey and review the motor asset base at 11kW rating and above.

This audit includes a non-intrusive survey of motors to collect, where possible, ratingplate data and information about the motors installed environments. The datacollected is analysed and the report provides information and commentary on themotor efficiencies found and opportunities for motor replacement and/or variablespeed drive applications.

Other relevant recommendations are made, including any necessary furtherinvestigations. These include a second stage intrusive audit for selected motors,using monitoring equipment to examine actual load cycle and absorbed power.

4.3.2 Survey

The survey was based on the motors identified by the site, which totaled 207, ofwhich the output power ratings were positively identified for 139 motors. Some ratingplates were missing and it was not possible to view all motors for access reasons they are inside air handling units. Blanks and/or comments in the data tablesindicate where data could not be obtained.

In the survey, each motor is given a number and this number is shown in the leftmost column of each table to enable cross reference. A record has been created forall 207 motors and the Excel database for this will be made available. Onlyinformation on the 139 motors is included in this report.

A summary of the key motor applications is as follows:

Compressed AirThere are three air compressors situated in building 449. Two compressors are ratedat 110kW, with the third rated at 132kW. None of the compressors have invertorcontrols fitted and they are controlled through a Honeywell control panel by way of a

simple on/off switch.

Air Handling UnitsThere are many AHUs across the site providing conditioned air for normal and cleanroom environments. They are all controlled by the site BMS system, and full detailsare included in section 4.6. Most fan motors above 11kW are controlled throughinvertors which are installed in the electrical cabinets. The invertors have a variety ofmanufacturers, although it was not possible to view them all as they were insidecabinets, some of which could not be opened. All motors are controlled throughpressure requirements managed through the BMS.


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Chilled WaterThere are three primary chillers serving the site situated in building 449. The chillersprovide cooled water for process and also condenser purposes for both the maincooling towers and a total of 6 further chillers around the site. Each chiller has aprimary cooling water pump (30kW), and a condenser water pump (45kW). Allmotors had soft start control which are monitored through the site SCADA system.

Within building 449, there are a total of five cooling towers, four with 2no 25kW fanmotors, and a newer one with 2no 22kW fan motors. These motors are controlledthrough the SCADA system and have 2 stage control only with no invertors or softstarts. It is understood that the older cooling towers may be replaced in the nextcouple of years due to corrosion issues.There are a further two York chillers situated outside the building which were notrunning at the time of the survey even though the external temperatures werereaching 25C. This is probably due to the fact that the cooling water is usedprimarily for processes, and the process load has been slowly declining over recentyears.

From the cooling towers there are three secondary cooling water pumps rated at90kW each. These serve a cooling water buffer tank and part branches off to servethe buildings. From the buffer tank, there are a further 2no pumps (75kW) pumpingwater around the site. All motors were invertor controlled.With building 427 there are 2no primary and 2no secondary chilled water pumpsrated at 15kW and 11kW respectively

Hot WaterThree steam boilers situated in building 227 provide steam to air handling units, lowpressure hot water heating circuits, processes and catering and domestic hot waterservices. There are four feed water pumps situated in the plant room each rated at22kW. There are several other pumps within the boilerhouse and also within smaller

plant rooms situated across the site. Motor sizes varied from 15kW to 22kW and hadvaried control methods.There are also three boiler draught fans, used to force air into the boilers to aidcombustion. These motors were rated at 15kW each, and each had invertor controlsfitted. Only one boiler was operating at the time of the survey due to the low demand.The most significant other plant room around the site is building 427 which hasLTHW preheat and reheat pumps

ProcessesThere are many processes across the site which require air and liquid. These aredivided into primary processes and secondary processes. The primary processesincludes storage tank pumps, natural gas compression pumps, incinerator related

pumps and borehole water pumps.

4.3.3 Basis of Analysis

The data collected has been analysed to:

Establish the motors efficiencies and rate these against current highefficiency standards.

Calculate potential return on investments for motor upgrades and/or variablespeed drive applications.

The analysis process and the results are described in detail as follows:


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High Efficiency Motors A definitionThe industry organisation CEMEP has produced a standard for motor efficiencies,now widely used in Europe and elsewhere, using the EFF rating scheme - EFF1being the highest efficiency class. EFF2 is an intermediate level and EFF3represents all other motors that do not meet the EFF2 level. The CEMEP ratingscheme covers 2 and 4 pole motors from 1.1 to 90kW. There is another standard forhigh efficiency motors - WIMES (Water Industry Motor Efficiency Standards). Thisstandard, defines minimum high efficiency motor percentages for 6 and 8 polemotors and for motors up to 400kW.

Using these two standards, we have a high efficiency benchmark for 2 and 4 polemotors from 1.1 to 400kW and 6 and 8 pole motors from 5.5 to 315kW. Thesestandards are used by the UK Government to define whether products are suitablefor its Energy Technology Product List and therefore qualify for tax incentives.1This report will use these standards to benchmark the existing motor asset base.

4.3.4 Global Metrics

Examination of the data yields the following information with an overall perspective:Quantity Percentage

Number of Motors Surveyed and rating obtained 137 100.0%

Total Installed Capacity (kW) 3782 100.0%

Number of Motors for which data was available tocalculate efficiency and to benchmark 53 38.4%

Number of Motors in High Efficiency Category (EFF1 orWIMES HE) 9 17.0%

Number of Motors with VSD's installed 12 8.7%

Rating of Motors with VSD's installed (kW) 761 20.1%

An estimate has been made of what the annual electricity consumption of thesemotors might be. This has been done using a bottom up method - from individualconsumption estimates for each motor. Using linear extrapolation, the consumptionof the total population of 207 motors rated at 11kW and above is also estimated.

kWh kg CO2

Estimated annual consumption by motors11kW (extrapolated to total population) 14,983,681 686,253 6,592,820

Site Electrical Consumption (2007) 41,670,000 1,908,486 18,334,800

Motors consume typically 60% of the electrical energy on an industrial site and thiswould indicate that these motors rated at 11kW and above, consume 60% of thatproportion. This seems a reasonable validation, on average, that the running hours

and load factors assumed are conservative. The data and assumptions used for theabove are shown in the table below:

Electricity Cost p/kWh 4.58

kWh to kg of CO2 conversion 0.44

Motor average utilisation factor 0.75

Site annual electrical consumption MWh 41,670

Proportion of electricity consumed by motors 60%

1See website: http://www.eca.gov.uk/NR/rdonlyres/F0F59A73-26D2-4590-8EF7-

56A87388373F/0/07MotorsandDrives_SingleSpeedMotors.pdf


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4.3.5 Efficiency Calculations

Where data has been available and recorded, full load efficiencies have beencalculated and are compared to the CEMEP or WIMES rating schemes see section4.3.3 for definitions.Full load efficiencies have been calculated, as follows:

Efficiency % = Rated power x 100Input power

and Input Power = 3 x voltage x full load current x power factor

The calculated efficiencies are compared with the high efficiency benchmarksdescribed in section 4.3.3. These benchmarks vary slightly with the number of polesof the motor. If otherwise not known, a 2 pole motor is assumed.

The table of motors with their efficiencies and the comparison with the relevantbenchmarks are shown in Appendix 7. From this table it can be seen that of the 53motors for which data was available to calculate an efficiency figure and benchmark,

9 are in classed as high efficiency. The table below shows the full breakdown:Quantity Percentage

Number of Motors Surveyed and rating obtained 137 100.0%

Total Installed Capacity (kW) 3782 100.0%

Number of Motors for which data was available tocalculate efficiency and to benchmark 53 38.4%

Number of Motors in High Efficiency Category (EFF1 orWIMES) 9 17.0%

Number of motors to EFF1 9 17.0%

Number of motors to EFF2 8 15.1%

Number of motors to WIMES HE 0 0.0%

Number of motors to EFF3 or WIMES Non HE 36 67.9%Number of Motors with VSD's installed 12 8.7%

Rating of Motors with VSD's installed (kW) 761 20.1%

4.3.6 High Efficiency Motor Replacement

The following procedure has been used to assess the potential energy saving andinvestment cost requirement for a selection of the motors if replaced with a highefficiency equivalent. From this a prospective return on investment (ROI), based onsimple payback, has been calculated. Results are shown in Appendix 8 for ROIs upto 10 years.

When viewing the results, the following points must be borne in mind:

Where full data is not available to calculate efficiency, when relevant, theEFF2/EFF3 boundary rating has been used, in line with CEMEP guidelines.Results are annotated where this assumption has been made.

Where actual load data is not available, a load factor of 75% is used. Resultsare annotated where this assumption has been made.

Full load efficiencies have been used in these calculations which would makethe projected savings conservative. Modern high efficiency motors tend tohave a flatter load/efficiency curve than conventional motors indeed in theEFF1 class the 75% load efficiency is usually equal or slightly better than the


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full load efficiency. In order to allow for this, an adjustment to the efficiencygain has been made as follows:

o Load factor > 80% 0% increase of gaino Load factor 60-80% 1.5% increase of gaino Load factor


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MotorNumber

BuildingNumber Building name Description / Application

MotorPower kW

3 449 Cooling tower compoundCooling water Pump No.1

Ingersol Dresser 90

4 449 Cooling tower compound

SECONDARY COOLED

WATER PUMP NO.2 75

19 449 AIR COMPRESSOR 2 110

20 449 AIR COMPRESSOR 2 132

22 449 CONDENSER PUMP 45

23 449 CONDENSER PUMP 45

58 436 INCINERATOR ID FAN 90

70 401 PRIMARY MANUFACTURING HTF PUMP MID 45

174 404 COMPRESSOR 90

It should be noted that a number of these motors appear in the list ofrecommendations for motor replacement or VSD application.

Motor Replacements - ScheduledPlan for the replacements identified in Appendix 8. Supplement and amend this listas further data is obtained.

Motor Replacements Breakdown and New PurchasesEnsure that motor replacements and new purchases are made with a high efficiencytype in accordance with the GSK Motor Management Policy.

Variable Speed Drive ApplicationsPlan for the VSD applications identified in Appendix 9. Develop the proposals in linewith the priorities indicated. Supplement and amend this list as further data becomesavailable. These applications will require further examination to validate theopportunities and to determine how best to implement them.


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4.4 Lighting

It is estimated that lighting accounts for around 9% of electricity consumption on thesite.

There has been a policy of using T8 long life lamps on the site and that these will begradually introduced as and when replacement of lamps takes place. Each processbuilding is responsible for its own maintenance and therefore lamps are replacedwhen they can be scheduled other than when they pose a hazard by not providinglight where essential. There appears at this time, no policy for lamp maintenancetherefore replacement and cleaning occurs only when required. The following tabledetails the energy consumption (excluding gear) for each lamp type:

Lamp type Wattage600mm T8 fluorescent tube 18

1200mm T8 fluorescent tube 361500mm T8 fluorescent tube 58

1800mm T8 fluorescent tube 72

Compact fluorescent 28SON High Pressure Sodium 250

The average lighting lux levels on the site are shown in appendix 1 which includes afull breakdown of the lighting survey. A summary of the information is shown below:-

Area Type of area Foyer Corridor Max Min

Building 225 Office 695 300 695 152Building 224 Office/ Workshop n/a n/a 790 242

Building 445 Office 1500 200 2639 184Building 468 Restaurant n/a n/a 702 408Building 427 Laboratory n/a n/a 2065 412

Building 400 Production area n/a n/a 2300 22

Building 401 Production area n/a n/a 1178 197Building 444 Contractors Compound n/a n/a 2555 142Building 405 Production area n/a n/a 708 70Building 403 Warehouse n/a n/a 946 89Building 407 Production area n/a n/a 845 139Building 425 Drum Store n/a n/a n/a n/a

Building 441 Storage Bays n/a n/a n/a n/aBuilding 435 Offices 532 300 996 131

Building 436 Incinerator n/a n/a 1162 187

The recommended lighting levels are shown in the table below:-Luminance(LUX)

Nature of Task Example Areas

50 No Detail required Cable tunnels, lifts, service ducts, indoor storagetanks

50 to 100 Visual task confined to movementand little perception of detail

Corridors, Bulk stores, changing rooms

100 to 150 Some perception of detail Loading bays, escalators, plant rooms, stores150 to 200 Constantly occupied interiors where

detail does not need to be perceivedAutomatic manufacturing processes, diningrooms, foyers and entrances

200 to 300 Continuously occupied interiors Goods packing, Libraries, Sports Halls,Assembly Halls, Workshops, warehouses

300 to 500 Details need to be seen General offices, shops, Labs, Machine shops,paint shops

500 to 750 Fine detail and colour differencesneed to be distinguished

Drawing offices, inspection areas

1000 Difficult visual tasks Electronic component assembly, tool rooms.


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4.4.1 Building 225

Building 225 is an administration building in the South East Section of the site. Thereare four floors in the building, Ground, First, Second and Third although the SecondFloor is currently not occupied. The installed lamps are a combination of T8

fluorescent tubes in double, triple and quadruple fittings in lengths of 600mm,1200mm and 1500mm with some compact fluorescent tubes. The recommendedLux levels were exceeded in some parts of the building.

It is recommended as the building is likely to be vacated in the future that a switch itoff campaign would be the most effective way of achieving savings.

4.4.2 Building 224

Building 224 is single storey and houses offices, conference centre & museum andSupport & Logistics. The office area, conference centre & museum are occupiedfrom 08:00 until 16:30 Monday to Friday. During the audit the conference centre and

museum were unoccupied with all the lights left on.

The Support and Logistics section operates normal working hours but is available24/7 for those with access requirements. They operate a system of dual controlwhich turns half the lights off outside normal working hours. In the warehouse thereis both fluorescent and sodium lamps which allows immediate light in the eveningand overnight when required and is well labelled, as indicated below. There are 2DCFL fittings which are left on overnight to allow those requiring to use the buildingenough light to access the switches, which are well labelled. Overall the lightingcontrol of the warehouse was well controlled.

The office area has glazing on two sides and therefore there is good natural daylightavailable. At the time of the survey, it was a bright sunny day and the internal blindswere closed with all lights switched on.

It is recommended that staff are encouraged to switch lights off rather than closeblinds to block out natural daylight.

4.4.3 Building 445

Building 445 is a three storey office block with a glass atrium at the entrance on thenorth side. The ground floor open plan area appears to be unused at the time of thesurvey other than a few cellular offices on the perimeter. The majority of lights areT5 fluorescent 1200mm which were all on during the survey even though there wasgood natural daylight available from the atrium, as can be seen from the photograph


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below taken at night. The recorded lux levels were between 1057 and 2639 at theground floor and balcony areas. It is clear from these high readings that these lightlevels were being achieved from the natural daylight source rather than the lightfittings.

It is recommended that photocells are fitted to the lights on the north side of thebuilding to take advantage of natural daylight available. It is also recommended thatPIR controls are fitted to washrooms. It is recommended that PIR/PEC controls areinstalled in the meeting rooms The Fleet, Loarning 8, The Dartford, Bexely, and theKaizen that have occasional use and also have daylight available.

4.4.4 Buildings 468

The restaurant is a catering facility of 180m2for all staff. The installed lamps are acombination of T8 fluorescent tubes in single, double, triple and quadruple fittings inlengths of 600mm, 1200mm and 1500mm with some compact fluorescent tubes. Asthe building was recently built there is already passive infrared technology in

occasionally visited areas such as the toilets. However, it was noted that the cateringstaff were not aware that they could turn off lights when leaving the building such asin the lobby area.

It is recommended that PEC should be installed to take advantage of the glazed westfacing wall.

4.4.5 Building 427

Building 427 is a two storey building of offices and laboratories which is open from8am until 10pm. The is a combination of 600mm and 1200mm T8 fluorescent lampsin triple and quadruple fittings with some 1500mm. There is a large roof skylight over

the staircase which provides good natural daylight. At the time of the survey thelights in the staircase were all on with a recorded lux level of 2065, when switched offthe lux level only dropped to 1962 lux. The corridor areas had lux levels between216 and 422 lux. This is higher than recommended levels.

It is recommended that PIR/PEC controls are fitted to the entrance lobby, staircase,The Swanky Meeting Room, Phoenix Suite and the Training Room.


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4.4.6 Building 400

Building 400 is a process building and is therefore occupied 24/7. The main process

area has high level glazing providing natural daylight. The majority of lights are1500mm T8 fluorescent. The entrance and lobby area exceeded recommended luxlevels which were due to the high level of natural daylight available.

It is recommended that PIR/PEC controls are fitted to the entrance lobby and Roxleymeeting room. It is also recommended that PIR controls fitted to the occasionallyvisited areas such as the wash rooms, locker room, meeting room and service voids.Due to the availability of natural daylight it is recommended that dimming PEC areinstalled on the south side of the process area.

4.4.7 Building 401

Building 401 is a process area and therefore occupied 24/7 with the lights beingpermanently on. The technical offices are only occupied during normal workinghours from 08:00 until 16:30 therefore there is an opportunity to switch lights off whenthese areas are not in use.

It is recommended that PIR/PEC controls are fitted to the south facing lobby andentrance and first floor meeting room, to take advantage of natural daylight. It is alsorecommended that PIR controls are fitted in those rooms that are occasionally visitedsuch as washrooms, locker room, meeting rooms, store rooms as well as the servicevoid areas. Full details are in the lighting appendix

4.4.8 Building 404

Building 404 is a process building and is therefore occupied 24/7. The main processarea has high level glazing providing natural daylight. The internal stairwell andcorridor exceeded recommended lux levels which, was due to the high level ofnatural daylight available.

It is recommended that PIR/PEC controls are fitted to the entrance lobby and PIRcontrols fitted to the wash rooms and locker room.


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4.4.9 Building 405

Building 405 is a production building on the North Site. As this is a key processbuilding, some of the lights are controlled through the distribution board and onpermanently. In some of the process areas, employees are in a room for 15 minutes

at a time only but the lights were constantly on. Also, there were some areas such asthe loading bay area where lights were on in one bay but not the other. The lightswere also constantly on in the service voids although these are only visitedapproximately once per week and for limited amounts of time. Where the lights arecontrollable, a people awareness campaign is an option to reduce energy usage.There is task lighting in the key process areas on the port holes so although therooms themselves had sometimes low light levels, such as 154 lux, the workingplane was adequate. The PPE room was a concern for the employees as the luxlevels were 831-1009; moreover the lights were not separately switched so there isenergy wastage and employee discomfort.

It is recommended that PIR/PEC control is installed in the entrance lobby to takeadvantage of natural daylight and PIR controls installed in the washrooms, showerrooms and service voids.

4.4.10 Building 403

Building 403 is the high bay warehouse for the site with associated administration.The installed lamps are a combination of T8 fluorescent tubes in single, double, tripleand quadruple fittings in lengths of 600mm, 1200mm and 1500mm with somecompact fluorescent tubes. There has been a re-lamping exercise in this building.

However, several fittings were out and some fittings needed cleaning suggesting thatsome maintenance is required. There was some good practice in the Meeting Roomas all equipment and lighting was switched off. However, in some of the offices, itwas noted that lights were on despite them being unoccupied. Also, in some offices,blinds were shut and lights despite natural daylight availability. The warehouse hasbeen extended and this was clear from the light fittings in the space. There were amixture of high and low bay SONs and some fittings we were unable to identify dueto their age.


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It is recommended that a voltage reduction control along with some PIR controlsshould be fitted within the warehouse. Voltage reduction controllers will reduce theelectricity consumption to the lamps in non high frequency fittings. Where lamps arehigh frequency, the drop in voltage will be compensated by an increase in currentthus mitigating any energy savings. There will be a slight dimming of the fitting butthis should be acceptable due to the current light levels

4.4.11 Building 407

Building 407 is the Grinding and Blending unit and is open 24/7. The lampsthemselves were mainly T8 although there were some T12 in the plant room andswitch room for example. There were some areas of good practice where areas wereunoccupied and lights out, however there were also offices which were unoccupied

with the lights on. Also, lighting was permanently on in the plant room although thiswas only really used for daily readings and a walk through.

It is recommended that PIR controls are installed in the washrooms, service voidsand plant room. It is also recommend that old T12 fittings are replaced with T8 longlife fittings in the switch room and plant room 04.


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4.4.12 Building 425

Building 425 is the chemical store. Most of these areas were lit and unoccupied.

There were some maintenance issues such as in the drummed solvent store wheresome lamps were not working. The lighting in here was mostly T12 fluorescent.

It is recommended that the T12 lamps and fittings are replaced with more efficient T8long life and that PIR controllers are installed to manage the lighting time moreefficiently. As can be seen from the photograph below the lights are permanently on.

4.4.13 Building 441

Building 441 is the Special Material and Cylinder store. In the main this was a wellmanaged area as most of the buildings were unlit and unoccupied. However, Q01was lit and S01 although the fridge itself was unlit.

4.4.14 Building 446 and 447

These buildings were not considered as it is due to be demolished and changed toCHP.

4.4.15 Building 435

Building 435 is a two storey building occupied by the Environmental ManagementCentre which consists of offices and laboratories and is in use 24/7. During thesurvey the majority of lights were on even although there was good natural daylightavailable. The office area within the reception area had switching that did not allowlocal control. On the ground floor 50% of the rooms that were not occupied hadlights on. The meeting rooms on the first floor which were not in use at the time had

all lights off although the corridor lights which had windows were all on. The new labarea has switches in zones from left to right across the area. The blinds in this areawere closed even although there was good natural daylight available.


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It is recommended that the switching in the office area is updated to allow localswitching in the offices at reception. It is recommended that staff are encouraged toswitch off lights when there is good natural daylight available, as indicated.

4.4.16 Building 436

Building 436 is a single storey building for the solids incinerator and is in operation24/7. The lights at the covered entrance were on although there was sufficient

daylight available. The main lighting is from low bay fitting with SON lamps withadditional 1500mm and 1800mm twin fluorescents and two Hi Bay lamps. The areais occasionally visited with lux levels internally ranging from 187 lux to 221 lux whichare within recommended guidelines for this type of area.

It is recommended that switches are clearly labelled to allow the entrance lights to beswitched off during daylight hours.


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4.4.17 External Lighting

A summary of the external lighting is shown in the table below:-

Area Lamp Type ControlsBuilding 222 250W Floodlight (4)

58W twin fluorescent tubes (4)Photocell / timer

Building 224 250W Floodlight (3) PhotocellBuilding 225Building 400 250W Floodlights (11)

58W twin fluorescent tubes (17)Photocell / timer

Buiding 401 250W Floodlights (Building 403 250W Floodlights (14) TimerBuilding 407 250W Floodlights (6)

58W single fluorescent tubes (6)Photocell / timer

Building 425 250W Floodlights (9) Photocell

Building 427 28W Compact Fluorescent (23)250W Floodlight (8) Photocell / timer

Building 428 250W Floodlights (4) PhotocellBuilding 429 250W Floodlights (5) PhotocellBuilding 435 250W Floodlights (4)

28W Compact Fluorescent (1)Photocell /timer

Building 436& 438 250W Floodlights (6)58W twin fluorescent (14)58W single fluorescent (6)

Photocell /timer

Building 441 18W twin fluorescent (20)250W Floodlights (10)

Photocell / timer

Building 445 250W Floodlights (4) PhotocellCar park Bldg 225 250W Floodlights (8) Photocell/timer

Car park 4 250W Floodlights (3) Photocell

The lights in the car park at the rear of building 225 were noted to be on at 11pm and

should have been controlled by a timer to switch them off at 9pm.


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Surveying the outside of the building during the hours of darkness, it is apparent thatthe majority of these lights were off where not required within the office areas but thatstore areas are on and only occasionally visited throughout the night.

Energy saving recommendations are as follows:-

a) It is recommended that presence detection controls (PIRs) are fitted intoappropriate office accommodation within the site as detailed in Appendix 1:

b) It is recommended that photo electric cell controls are installed as detailed inAppendix 1

These projects will need to have further design work to ascertain firm costs as wiringmodifications may be required.

c) It is recommended that outside lights have voltage reduction controllers fitted asdetailed in appendix 1. These units have an astronomical clock installed whichwill ensure that the lights are turned off during daylight periods.

Savings related to the above measures are estimated at 491,000 kWh ( 22,500)with an estimated capital expenditure of 62,000. A full breakdown of thesemeasures is included in Appendix 1.


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4.5 Power Quality and Availability

4.5.1 Methodology

All electrical substations on site were visited with a view to establishing the following: Data on any installed PFC and its status at the time of visit; Data on installed transformers, such as rating, present tap settings, etc; Voltage levels at the time of visit, obtained from installed instrumentation; Load power factor at the time of visit, obtained from installed instrumentation (if

available); Loading of LV panels at the time of visit, obtained from installed instrumentation. The types of equipment installed in each building, e.g. process loads, office-type

equipment, etc. This information was obtained from GSK utilities staff on site.

A copy of the site single line diagram is included in Appendix 4 for reference.

4.5.2 Power Factor Correction

Of the 22 transformers on site, 14 have PFC applied to their loads, 7 have no PFCand 1 is unknown. Of the 14 that have PFC applied, 9 are in service and 5 havebeen taken out of service. Full details of the site power factor is included in Appendix5.

The table below displays the transformers whose PFC has been taken out of service.

Assoc.Tx No.

PF READING LOAD TYPES

T228-1 ALTERNATEDBETWEEN 0.7AND 0.9 (LAG)

MIXTURE OF OFFICES AND INDUSTRIAL AREAS WITH ASSOCIATEDTEMP CONTROL PLANT

T422-1 0.82 (AVE)FEEDS BLDG 401 - PRODUCTION BUILDING - MOSTLY INDUCTIVELOADS: PUMPS, AGITATORS, PUMPS, AHU, CHILLERS

T422-3 0.86 (AVE)FEEDS BLDG 400 - PRODUCTION BUILDING - MOSTLY INDUCTIVELOADS: CHILLERS, AHUs, NITROGEN PLANT, DUST EXTRACT EQPT.

LABELLED PFC UNIT 120-3 (WITHIN BUILDING 422)*

1.0LV PANEL 422-4: NEW PANEL RETROFITTED TO EXISTING 3x 422 LV

PANELS. RELATIVELY LOW LOADING (41A/Ph)

T225-1 0.91OFFICE TYPE LOADS, SOME AIR HANDLING, LARGE CHILLERDURING SUMMER MONTHS

*AWAITING INSTALLATION DURING VISIT FOR LV PANEL 422-4?

The following table displays the transformers which have no PFC applied to theirloads.

Assoc.Tx No.

PF READING LOAD TYPES

T467-1 0.99 T467-1: LARGE MULTI-STAGE CHILLER, SIGNIFICANT LIGHTING LOAD

T467-2PANEL INSTRUMENTATIONINDICATES ZERO PANEL LOAD

T467-2: TRANSFORMER NOT LOADED DURING VISIT

T469-1 0.973 T469-1: 2x CHILLERS

T469-2 1.0 T469-2: NEGLIGABLE LOAD (6A/Ph)

T427-1 0.91T427-1: PREDOMINANTLY SPECIALISED LAB EQUIPMENT, ALSOSIGNIFICANT AIR HANDLING LOADS, LARGE CHILLERS, SOMEOFFICES.

T241-1 NO PF METER

T241-2 NO PF METER

T241-1, T241-2: BOILER HOUSE PLANT: VARIOUS PUMPS, FANS,COMPRESSORS. ALSO GAS TURBINE CONTROLS, UPS FOR SCADASYSTEM, WATER TREATMENT PLANT.


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The use of variable speed drives (VSDs) has generally increased over the years, dueto their energy saving capabilities. VSDs, by their principle of operation, generateharmonic currents which can interact with standard types of power factor correction,causing damage to the PFC. Its likely that the Dartford site has added VSD controlto motors over the years, and possible that PFC originally considered appropriate,given building load types at the time of their specification, may no longer be suitable.It is also possible that the five PFC units taken out of serviced mayhave failed due tothis reason.

As a general rule of thumb, if the amount of non-linear load (of which VSDs can beconsidered), compared to the total connected load exceeds 15%, detuning reactorsmust be used.It is therefore recommended that the suitability of PFC units (both in and out ofservice) be reviewed, with respect to local load types. Temporary power qualitymonitoring, performed either over a week long or snapshot period (if carried out at arepresentative time), can be used to determine appropriate types of PFC. Schneiderwould be happy to assist you with this task, if required.

Transformers with PFC Taken Out Of Service

From the above table, due to the low power factors recorded during the visit, it isrecommended that the suitability of the PFC connected to the loads of transformersT228-1, T422-1 and T422-3, be reviewed, with a view to either re-instatement ormodification/replacement.

T422-4 had a relatively low load during the site visit and if this load observed wasrepresentative, the need for the PFC applied to this transformers load to be re-instated/modified/replaced is not seen as urgent.

Regarding the load of T225-1, although the power factor reading recorded during thevisit was not low (0.91), it should be noted that this equipment was visited on 1 stMay2008, when its likely that the connected chiller wouldnt have been operating. Onceoperating, it expected that the load power factor will reduce, and again, it isrecommended that the suitability of the PFC connected be reviewed, with a view toits re-instatement/modification/replacement.

Transformers with No PFC installed

From the table above, the same reasoning used for the load of T225-1 can beapplied to the loads of transformers T467-1, T469-1 and T427-1 regarding theoperation of connected chiller loads. Therefore it is recommended that feasibility be

investigated regards the application of PFC to the loads of these transformers.

Based on the loading observed on transformers T467-2 and T469-2, application ofPFC to the loads of these transformers is not required.

There is no PFC applied to the loads of transformers T241-1 and T241-2. It isassumed that Generator 1 will perform power factor correction for this building, ifparalleled with the mains supply. If this assumption is correct, no further actionregards the application of PFC would be required.


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Benefits of PFC

The benefits of improving power factor include: Energy cost reduction: If a consumer is being charged for reactive power use; Possible reduction in a sites maximum demand (see below). Reduction in circuit currents: Associated transformer and conductor losses reduced on consumers network

and utility companys networks; Release of additional network capacity. CO2reduction The BEAMA Capacitor Manufacturers Association calculates

that every kVAr of PFC installed results in a reduction of 160kg of CO2generated per year (through reduction of losses on the entire UK transmissionand distribution network).

Note: It is reported that a power factor correction equipment audit and inspection has

recently been undertaken (by others) so some issues stated in this report may be inthe process of being addressed. Therefore, no further information orrecommendations regarding power factor correction will be contained within thisreport.

4.5.3 Non-linear Loads/Neutral Conductors

The majority of transformers on site utilise LV neutral conductors rated at 50% of thecross sectional area (CSA) of the associated phase conductors. In the past, 50%rated main neutral conductors were frequently specified in buildings before thewidespread use of switched mode power supplies (SMPS). Full details of the datacaptured is included in Appendix 6.

SMPSs are used in common office equipment such as PCs, photocopiers, faxmachines, etc. and these devices generate harmonic currents, some of which dontadd vectorally in the neutral conductor (and thus dont cancel each other out as isthe case with linear type loads). This effect results in higher neutral currents thanthose anticipated when the network was originally designed.

The table below lists the transformers that utilise 50% rated neutrals and supplybuildings that could contain a high proportion of SMPS-type loads:

TRANSFORMER LOAD TYPES

T228-1

MIXTURE OF OFFICES AND INDUSTRIAL AREAS WITH ASSOCIATED TEMP

CONTROL PLANTT467-1 LARGE MULTI-STAGE CHILLER, SIGNIFICANT LIGHTING LOAD*T437-1 MIXTURE OF OFFICES, LABS AND MOTOR LOADS

T427-1PREDOMINANTLY SPECIALISED LAB EQUIPMENT, ALSO SIGNIFICANT AIRHANDLING LOADS, LARGE CHILLERS, SOME OFFICES.

T225-1OFFICE TYPE LOADS, SOME AIR HANDLING, LARGE CHILLER DURINGSUMMER MONTHS

*Electronic ballasts assumed


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4.5.4 Recommendations

Of the 22 transformers on site, 14 have PFC applied to the associated main

LV panel, 7 have no PFC and 1 is unknown. Of the 14 that have PFCinstalled, 9 are in service and 5 have been taken out of service. It is possiblethat PFC originally considered appropriate, given building load types at thetime of their specification, may no longer be suitable. It is also possible thatthe five PFC units taken out of serviced mayhave failed due to this reason. Itis therefore recommended that the suitability of PFC units (both in and out ofservice) be reviewed, with respect to local load types.

Due to the low power factors recorded during a site visit, it is recommendedthat the suitability of the PFC connected to the loads of transformers T228-1,T422-1 and T422-3, be reviewed, with a view to either re-instatement ormodification / replacement.

Based on the relatively low loading observed at transformer T422-4 during a sitevisit, the need for the installed PFC to be re-instated/modified/replaced is notseen as urgent. Also, based on the loading observed on transformers T467-2and T469-2, application of PFC to the loads of these transformers is not required.If the assumption that Generator 1 is paralleled with the mains supply is correct,no further action regards the application of PFC to the loads of transformersT241-1 and T241-2 would be required.

It is recommended that the suitability of the PFC applied to the loads oftransformers T225-1, T467-1, T469-1 and T427-1 be reviewed, with a view toits re-instatement/modification/replacement.

The benefits of improving power factor could include: Site energy cost reduction: Reduction in circuit currents: UK CO2reduction

It is also recommended that true rms power monitoring be performed at thetransformers T228-1, T467-1, T437-1, T427-1 and T225-1 to identify whetherharmonic currents are prevalent in the in the network. Mitigating action and /or neutral conductor replacement may be required depending on the resultsof such surveys.


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4.6 Building Controls & Building Management Systems

4.6.1 Regulatory requirements

There are several regulatory requirements relating to pharmaceutical processes thatheating, ventilation and air conditioning should adhere to, primarily in the clean roomenvironment. Cleanrooms are classified by the cleanliness of their air. This is doneaccording to ISO 14644-1. This is an international standard, having been adopted bythe European Union in 1999, and the USA in 2001

4.6.2 Description of Building Management Systems (BMS)

The site BMS system is split into four main systems and some stand alone systems.The systems are either operated by the site FM (Johnsons Controls) or by GSKthemselves for more critical areas. It is understood that building log books arent

currently used for plant room modifications, and it is common for control strategies tobe out of date. This causes plant to be switched to manual which in turn results inalarms to the BMS system. The plant is subsequently set back to auto which in turncauses the plant to fail.

The BMS systems can be summarized as follows:

Site Coverage BMS Type Functionality Head endBoilers, Chillers, CoolingWater, Borehole Water

SCADAHoneywell

Monitors only Bldg 225

Building 225 Offices Trend 963 Bldg 225Building 427 R&D Siemens Visonik

Insight

Bldg 427

Building 435EnvironmentalManagement

Siemens VisonikInsight

Monitors Nitrogen meter Bldg 407

Building 445 Offices Siemens VisonikInsight

Monitors & Controls HVACsystem, LTHW, DHW andvarious extract systems

Bldg 407

Building 400 Production Siemens VisonikInsight

Monitors & Controls AHUsand extract systems

Bldg 407


Monitors & Controls AHUsand extract systems

Bldg 407

Building 403 Warehouse Siemens Visonik

Insight

Monitors & Controls DHW

and LPHW and some process

Bldg 407


Monitors & Con

Documents

Dartford Electrical Energy Survey Report Rev F