Harlan Labs Wyton HVAC Energy Audit R1

HVAC Energy Audit Harlan Labs, Wyton

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HVAC Energy Audit and Optimisation Report

for

Harlan Laboratories, Wyton

NAME: Mir Ali

Date: 18/06/2012

Project No. 12070

Rev R1


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1 Contents 1.0 Executive Summary .................................................................................................................... 3 1.1 Recommended Energy Projects ............................................................................................. 6 Regulatory Projects: ............................................................................................................................... 6

Low Cost Projects: ................................................................................................................................... 7

Medium Cost Projects: ........................................................................................................................... 7

Sustainability Projects: .......................................................................................................................... 8

2.0 Introduction and General Systems Overview .................................................................... 10 3.0 Energy Performance Benchmarks .......................................................................................... 15 4.0 Assessment Findings and Observations ............................................................................... 17 5.0 Documentation, Maintenance, Specific Fan Power & Metering .................................. 21 7.0 Summary Condition Appraisal and Maintenance Overview ................................... 23 8.0 Capital Investment Opportunities .......................................................................................... 25 9.0 Action Plan / Way Forward .................................................................................................. 27 10. Conclusions...................................................................................................................................... 28 11. Sample FRS (Functional Requirement Specification) ..................................................... 29


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1.0 Executive Summary

Harlan Laboratories is a leading provider of essential, pre-clinical and non-clinical contract research,

research models, lab animal diets, and services to the pharmaceutical, biotech, medical device,

agrochemical, and chemical industries and other research organizations.

Harlan Labs provide customers with products and services to optimize the discovery and safety of new

medicines and compounds.

The client had requested us to undertake a Building Energy and Sustainability Feasibility Assessment for

Harlan UK, Wyton, Huntingdon, Cambridgeshire. This is in response to reducing the energy consumption

of the facility in recognition of increased policy compliance legislation, operational cost optimisation and a

continuing business driver to deliver improved building operational performance.

Taking into account the design and age of the building and plant deployed the inspection has identified

significant opportunities of improving Air Conditioning system performance. These include improved

maintenance schedules, optimising the operation of chilled water plant, control strategy optimisation and

implementation of improved building systems energy and process operational metering, monitoring and

targeting. Cognisance should be made of European revised legislation to future proof the facilities.

During inspection it was observed that the site does not currently meet the Government and Industry

stipulated Guidelines in some areas. The Wyton site (Beagles) does not have any form of cooling which

would be needed to meet maximum temperature requirements. Based on the site visit, there are

operational problems with the heating only AHUs due to the age of the plant. Based on the Home Office

(HO) Code of Practice for the housing and care of animals in designated breeding and supplying

establishments, and HO Animals (scientific procedures) Act 1986 Pg 31 requires some form of cooling to

be provided in order to attain temperatures between 15-24 Deg C for beagles to deal with extremes of

temperature.

It was also noted that the site lacks an air filtration philosophy, a minimum of F7 filtration is

recommended to ensure operator safety, studies conducted in the US by the Environmental Epidemiology

Program, Department of Environmental Health provide direct correlation between PM2.5 and increased

incidence of cancer and respiratory ailments. (The Concentration-Response Relation between PM2.5 and

Daily Deaths by Joel Schwartz et al ) carried out over six U.S. cities.

As the site is an animal research facility, we would expect that protection of pure breeds from

contamination and outside pollutants is a primary goal. We would highly recommend that a filtration

philosophy be developed at site, as the site may be susceptible to airborne viruses from the nearby

testing facility within site which could wipe out existing stocks and poses a business continuity risk.

Due consideration should be made to comply with European regulations when Directive 2010/63/EU will

take full effect from 1 January 2013, these regulations prescribe the temperature, relative humidity, space

ventilation, lighting, and noise levels within these spaces, which require a provisional 1520 ACPH.


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The survey covered the Inspection of HVAC systems, assessing the performance of fans, and associated

heating and cooling electrical/gas loads, in order compare performance with industry standards and to

identify energy savings whilst maintaining their minimum performance requirements. A key observation

was the lack of effective controls at site; it would appear that only Building 3 is connected on the BMS

with out of range alarms with the outstation located at Hillcrest. Operational problems are being logged

by the site personnel with no means of viewing control parameters at site, it is highly recommended that

the site incorporate a BMS outstation with all plant operations on a BMS outstation to have effective

control of critical monitoring parameters to ensure HO compliance for recording temperature and

humidity.

While reviewing the onsite records, there were no Operational and Maintenance manuals, Commissioning

Data for the Mechanical plant including commissioning results ( including flow rates) for the AHUs were

not found with the O&M Manuals. The As Built record drawings and subsequent amendments were not

available at site. Planned Preventative Maintenance Records indicating the frequency of maintenance /

schedules and building log book were not made available during the visit.

We would recommend that the site carry out a re-commissioning exercise in order to validate air flow

rates in order to check for compliance with HO regulation.

The site currently has 5KW cooling capacity to the Archives room, which does not warrant an Air

conditioning inspection.

In summary the existing HVAC system chilled water operation at Harlan UK, Wyton, Huntingdon,

Cambridgeshire would benefit from optimisation to enable ongoing operational efficiencies to be realised.

Replacement of AHUs in 1,2a,2b,3,4,5,11,12,24,25,25a,26,27,28 which have a heating only AHU should

be considered as soon as possible to ensure Regulatory compliance and plant security.

Buildings 16,17,18,19,20,21 housing whelping do not have an AHU, but rely on a rudimentary wall mounted supply and extract fan with a local gas fired heater in the space coupled with infra red localised heating in the cages to provide a temperature of 26-28 Deg C to comply with Home office regulations. It is not clear whether adequate air changes and temperatures needed are being attained. It is recommended that these areas be reviewed for compliance. Electrical supplies to the site is via 2 Nos feeds, the top side (Admin areas, Buildings 1,2a,2b,3) and

bottom side (4,5,11,12,16,17,18,19,20,21,24,25,25a,26,27,28). The top side is served via a 400A main

breaker whereas the back side is served via a 200A main breaker. The site also has a backup generator

provision, the top side being served via a 100KVA generator, while the bottom side served via a 200KVA

generator.

It would appear that the generator serving the top side is clearly undersized for its duty and requires an

upgrade, while the bottom side generator appears to currently meet the loadings. We would recommend

an electrical audit to review the existing electrical infrastructure at site with a view to incorporate

additional cooling loads.


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We have provided a breakdown of the various energy efficiency measures with a priority listing to enable

the client to make a judgement for considering various energy efficiency measures needed to run the

plant in an optimum and energy efficient manner.

A summary of projects identified are listed below.

Elec

kWh/yr Elec /y

Gas kWh/yr

Gas /y

Yr Tons

Project Title Cost Simple

Payback CO2

saving

Regulatory:

AHU Ductwork cleaning (Per Bldg) 500.00

Validation of HVAC System 50,000.00

DEC Site wide 1200.00

Oil Tank Plinths 30,000.00

Low Cost Projects:

Energy Efficient Boilers for Admin Bldg

30,000.00

Medium Cost Projects:

Implement AM&T System 170,000.00

Energy Efficient AHUs per Building 200,000.00

BMS Upgrade 200,000.00

Sustainability Projects:

Sun Pipes / Natural Daylighting per Bldg

60,000.00

Evaporative Cooling / Borehole Cooling (Site wide)

200,000.00

Elec Saving kWh

Elec Saving /y

Gas kWh/yr

Gas /y

Investment

Yr Tons

Sub-Total


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1.1 Recommended Energy Projects

The Audit-identified projects have been grouped into 4 different categories namely Statutory / Regulatory requirements, Low cost options, medium cost (Infrastructure upgrade) and Sustainability projects which are discussed below. All costs included here are budget costs (25% subject to detailed design):

Note: Regulatory Projects may not be energy reductions, but EECO2 will ensure energy efficient solutions

are proposed to minimise increases.

Regulatory Projects:

1. AHU Ductwork Cleaning: The Supply air socks on the AHUs were found to be dirty. It would

appear that there is poor air filtration regime at the air intakes at the heaters. Existing ductwork

has not undergone a cleaning regime. Airborne particulate matter present at site clearly presents

a health hazard. Minimum F7 requirement for protection, along with yearly washing should be

carried out, recommend a spare set of F7 filters.

Budget Cost: 500 for cleaning and disinfecting per AHU to provide a hygiene and safety deep clean.

2. Validation of HVAC System: Based on the Code of practice for the housing of animals in designated breeding and supplying establishments, Laboratory Animals Breeders Association (LABA) Guidelines on the care and housing of animals bred for scientific purposes. The Industry Guidelines specify 10-12 changes of fresh or air conditioned air per hour distributed throughout the room. It would appear that the air flow rates in the Buildings currently do not meet the regulatory standards mentioned therein. It is advisable that the ventilation system be validated in all the Blocks as part of the Home Office regulatory compliance.

Budget Cost: We would recommend that a budget Capex of 50K be set aside for carrying out recommissioning of the HVAC systems at site in order to determine current air changes being achieved.

3. Energy Performance Certificate (EPC) / Display Energy Certificate (DEC): An

Energy Performance Certificate (EPC) is a statutory requirement in order to comply with the

Energy Performance of Buildings Directive and UK National legislation. While, it is not mandatory

for the site currently as it is privately owned, and would be needed while buying and selling the

premises. The client might wish to have an EPC certificate in order to determine the buildings

asset rating.

Display Energy Certificate (DEC) while not mandatory, shows the actual energy usage of a

building, the Operational Rating, and help the public see the energy efficiency of a building. The

DEC should be clearly displayed at all times and clearly visible to the public. A DEC is valid for 12


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months and needs to be updated annually. The accompanying Advisory Report is valid for 7

years. The client might wish to carry out a DEC for public display in order to improve Public

Relations (PR) in the local community.

Budget Cost: A Budget cost would be 3K for carrying out an EPC and report, while a DEC would cost about 1200. As CIBSE accredited Energy Assessors, we can carry out the above works.

4. Oil Tank plinths: During the survey, it was noticed that the oil tank plinths was not compliant with the Oil storage regulations, some of the oil tanks were mounted on bricks, this is not as per DEFRA guidelines for oil storage. Failure to comply is a criminal offence. The site could be fined up to 5,000 by DEFRA.

Budget Cost: We would assume that the cost of Civil works for providing adequate plinths including providing an adequate concrete base for the Oil tanks located in the Admin courtyard and other areas at site would be 30K. We shall be happy to review this to make it DEFRA compliant.

Low Cost Projects:

5. Energy Efficient Boilers for the Admin Block: The existing boilers in the Admin block were installed in the 1980s and are well past the CIBSE recommended design life expectancy of 15 years. Due to their present age, there is insufficient combustion of the boilers resulting in acrid smoke in the offices during start up, the frequency of maintenance has increased many fold. These boilers have an efficiency of 60-70%. We would recommend that these be replaced with energy efficient Boilers which have an efficiency greater than 95%, the boilers selected shall be fully modulating, have weather compensation and incorporate an intelligent boiler controller for energy optimised operation.

Budget Cost: We would assume that the cost of supply and Install of 2 Nos energy efficient Boilers for the Admin areas would be 30K.

Medium Cost Projects:

6. Implement an Automatic Monitoring System: The site does not have adequate sub metering on the blocks, individual auxiliary plant serving the building do not have a dedicated energy input or hours run meter. Meter readings are read and recorded on a regular basis. It is estimated that there is a 5% reduction in energy consumption due to an effective M & T system.

Budget Cost: The cost of supply and Install of an automated M&T system would be 170K.


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7. Energy Efficient AHUs for various buildings: The AHUs serving Buildings 1,2a,2b,3,4,5,11,12,24,25,25a,26,27,28 are more than 30 years old and showing signs of failure, it is our considered opinion to replace these with Low Energy AHUs capable of providing 10-12 AHCP for these Buildings, while incorporating system redundancy to allow the AHUs to function during downtime. Buildings 16,17,18,19,20,21 housing whelping do not have an AHU and relies on wall mounted fans for achieving the air change rates, It is recommended that these areas be reviewed for compliance.

Budget Cost: We would assume that a budget cost of supply and Install of new energy efficient AHUs per building would be 200K.

8. BMS Upgrade: The site does not have a BMS system it is recommended that the site incorporate a BMS system and control panel.

Budget Cost: We would assume that the Budget cost for supply and install a new BMS Trend system and incorporating energy efficient strategies would be 200K.

Sustainability Projects:

9. Sun Pipes: The Lighting system at site is generally good with ample Lux levels achieved within the barriers. The site has managed to replace nearly all of the T8 fluorescent light fittings with T5 light fittings. Lighting at site represents a major load due to lack of cooling at site, consideration could be made to reduce electrical energy consumption by incorporating sun pipes and incorporating dimming features on the existing T5 light fittings, this would help reduce the need for procuring additional electrical supplies at site due to added cooling requirement to comply with the mandated regulatory requirements.

Budget Cost: A Budget cost for installing sun pipes per building (42 X 16.5 Mts) would be

about 60K with savings of 15K in energy costs. This would give a Return on Investment (ROI)

based on energy savings at 4 Years.


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10. Evaporative Cooling / Borehole cooling: The site currently does not have any cooling, but in order to comply with home office regulations, there is a need to incorporate cooling on the AHUs, which would generally account for nearly 30-40% of the total electrical consumption at site.

There exists an opportunity to reduce energy consumption by reviewing the process cooling loads at site. We would propose to review the process cooling loads at site and come up with a proposal to use evaporative cooling for the AHUs coupled with Bore Hole cooling thereby resulting in massive energy savings to be made. The existing chillers could provide useful back-up while maintenance is being carried out on the borehole. Typical ground water supply temperatures are in the range of 6-10C and typical re-injection temperatures 12-18C (subject to the requirements of the abstraction licence).

Budget Cost: It is difficult to put a Budget cost for this option, as a detailed study is required

to look at Ground Water levels / Ground water abstraction for large yields. As a rough estimate,

we would put it at 200K.


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2.0 Introduction and General Systems Overview

Harlan UK, Wyton, Huntingdon, Cambridgeshire PE28 2DX consists of several buildings in the campus. The

various blocks house the stock, brood and whelping along with an Office and Administration area. Each of

the Blocks is generally self contained with an AHU, DHW provision with an oil tank / LPG connection. The

site also houses a private research facility, access was not available to review that building and has not

been included in our report.

Incoming services

The incoming water services to site is via a single metered supply within the site premises with 6 Nos

water manholes provided for its distribution. Electrical supplies to the site is via 2 Nos feeds, the top side

(Admin areas, Buildings 1,2a,2b,3) and bottom side (4,5,11,12,16,17,18,19,20,21,24,25,25a,26,27,28). The

top side is served via a 400A main breaker whereas the back side is served via a 200A main breaker. The

site also has a backup generator provision, the top side being served via a 100KVA generator, while the

bottom side served via a 200KVA generator.

It would appear that the generator serving the top side is clearly undersized for its duty and requires an

upgrade, while the bottom side generator appears to currently meet the loadings.


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The site is served by a number of Distribution boards located in the various buildings, some of the boards

appear to be dated, it is recommended that a periodic inspection report of the electrical installation be

carried out to achieve regulatory compliance.

There is no gas supply in the area, the heating for the entire site is met via gasoil fired / LPG boilers

located all around the site. The site is not connected to the mains sewer and operates a sewer /effluent

treatment plant for soil waste.

LPG Layout

The site has an extensive network of LPG tanks and piping at site providing heating for the buildings,

domestic hot water requirement is met via localised point of use water heaters.


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In order to achieve compliance with Home Office regulations along with the fact that electrical supplies

are stretched, we would recommend a Gas based Heat pump solution providing heating, cooling and

Domestic Hot water to the buildings. We could carry out a feasibility study and costs for the site once

building treated floor areas are made available.

Offices and Admin Block

The office areas are heated via 2 Nos oil fired boilers located within the building. DHW for the offices is

provided via point of use electric heaters. There is no cooling at site, with cooling being provided to the

archive room via a 5KW heat pump. The office and admin block heating is fed of a 2500 Litre oil tank

located in the courtyard. The oil tank is currently being supported on bricks, not consistent with DEFRA

regulations which prescribe a proper foundation.


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Buildings 1,2a,2b,4,5,11,12,24,25,25a,26,27,28

Buildings 1,2a,2b,4,5,11,12,24,25,25a,26,27,28 house the brood, and stock. These buildings are served

via a primary Air Handling Unit (AHUs), these are constant volume systems providing fresh tempered air

to the barriers. The Primary AHUs are a once through type units with the extract air from the building

vented through openable louvers. There is no HVAC control optimisation strategy e.g. Night setback,

booster facility, and or free cooling on the AHU.

The AHUs for these buildings is fairly basic, with air being heated by gasoil / LPG fired heaters. The

centrifugal fan is housed within an enclosure, and connected to air socks which serve the barriers. It

would appear that these AHUs do not have adequate level of filtration. It is important to have the extract

air ducted as it could provide a possible path for contamination of the pure stock by airborne viruses.

We would recommend that air quality / filtration be reviewed in order to comply with the European

Regulations Directive 2010/63/EU will take full effect from 1 January 2013.


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Building 3, 29

Building 3 houses the Whelping puppies, the AHU serving building 3 consists of 2 Nos modern AHUs. The

air handling unit is made up of a supply and return air sections, this consists of an inlet louvre, a panel

filter, Gas fired heater and a forward curve belt driven centrifugal fan driven by a 415V 3 phase motor.

The AHU incorporates a recuperator before the air is discharged into the atmosphere. Air is extracted

from the conditioned space via a centrifugal fan, driven by a 415V 3 phase motor. The AHUs are on

constant speed drive. Heating for the Building 3 is provided Gas fired heater batteries located in the AHU.

The air-handling units operate under the control of a BMS system, which is located at Hillcrest.

The AHU is interfaced with the fire alarm, in case of a fire, the Supply fan is shut down, and the extract fan

is also shut down. The fire philosophy of the building is not well defined. The HVAC plant for the barriers is

being operated continuously.

Building 29 is served via 2 Nos modern AHUs, this building was being constructed during the survey; no

details of the AHUs were available for review.

Buildings 16,17,18,19,20,21

Buildings 16,17,18,19,20,21 houses the Whelping puppies, ventilation for these buildings is provided via

rudimentary supply and extract wall mounted fans coupled with a gas fired heater located within the

buildings along with localised infra-red heaters in the cages. Home Office regulation for puppies requires a

local environmental temperature of 26-28 Deg C for at least the first 5-10 days of life. It is not clear how

these parameters are being recorded / monitored at site.

Actual electricity consumption during 2011 was 359,055 kWhs costing 44,881.87 based on an electricity

tariff of 12.65 pence/kWh (Inclusive of VAT at 17.5%), the site uses Gasoil Class A2 32 Sec1 as a heating

medium along with LPG, unfortunately there is no consumption data available to carry out an energy

benchmarking.

Harlan Labs, Wyton was constructed in the 1980s; the thermal elements and standards reflect the

building regulations level of compliance at the time of construction in 1980. This building has not

undergone any significant re-development works over the years and the services match the age of the

building. The car park was later added to the main building.

The construction of Harlan Labs, Wyton is based on a concrete frame and floors with block cladding walls

with corrugated insulated panel roofing. The windows are generally double glazed with Aluminium frames

which are part of the original installation.

Projected energy savings and costs are based on 2011 energy prices.


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3.0 Energy Performance Benchmarks

The building consumes significant amounts of gasoil, LPG and electricity for its operation to provide for

heating, ventilation, lighting, small power and DHWS services.

The table below relates to the energy consumption of the building, unfortunately treated floor area of

each building including total production areas are currently unavailable for carrying out an energy

performance benchmarking assessment. Electrical Costs below are based on 12.65p / KWHr for Electricity.

While this data is generally accurate to an extent, we would recommend an AMR (Automatic Meter reading)

for the Gasoil meter, so as to enable a more accurate degree day regression analysis be carried out for the

site.

Table 1 Harlan Labs, Wyton Building Energy Use 2011 (based on datasheet provided by client)

Utility Annual Energy & Water Consumption

Annual Cost CO2 emissions1

kWHr/year % /year % tonnes

Electricity 359,055 44,881.87 195.6

LPG Not Known

Gasoil Not Known

Total Utility

Costs

Total CO2 Emitted for utilities (tonnes)

1. Carbon Dioxide conversion factors based on carbon Trust.

Unfortunately, we do not have LPG and Gasoil consumption figures in order to evaluate energy mix of

various fuels used at site.


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Regression Analysis

The degree day plot allows us with a comparison with weather related measure and is a powerful tool for

energy managers to evaluate the performance of buildings. This shows the relationship between the

actual external temperatures and the electrical consumption on site.

Based on the data provided by the client, we only have electrical consumption at site, as there are no

individual meters monitoring oil consumption, Gasoil and LPG monthly / quarterly receipts do not provide

adequate granularity to carry out an accurate regression analysis.

Unfortunately, we are unable to carry out a regression analysis due to lack of data.

29,121 29,181

31,807

29,847 30,376

29,157 29,446 29,198

28,589

30,176 30,122

32,035

Electricity Consumption- 2011

Electricity (KWHr)


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4.0 Assessment Findings and Observations

AHUs serving Buildings 1,2a,2b,4,5,11,12,24,25,25a,26,27,28

Buildings 1,2a,2b,4,5,11,12,24,25,25a,26,27,28 house the brood, and stock. These buildings are served

via a primary Air Handling Unit (AHUs), these are constant volume systems providing fresh tempered air

to the barriers. The Primary AHUs are a once through type units with the extract air from the building

vented through openable louvers.

The AHUs for these buildings is fairly basic, with air being heated by gasoil / LPG fired heaters. The

centrifugal fan is housed within an enclosure, and connected to air socks which serve the barriers. This

arrangement results in high eddy losses and is not recommended. It would appear that these AHUs do

not have adequate level of filtration. There is no data available at site indicating air flow rates of these

AHUs, air socks was found to be damaged in building 2a, many of the air socks were dirty needing a

cleanup.

Based on Home Office regulations, some form of cooling is required to provide temperatures between 15-

24 Deg C for beagles to deal with extreme ambient temperatures. Based on the site operational log, the

gas fired burners are 30 years old well past their recommended life and are showing signs of increasing

failure, this has resulted in an inability to meet the HO recommended temperatures.

Ventilation and heating for buildings 16,17,18,19,20,21

Buildings 16,17,18,19,20,21 houses the Whelping puppies, ventilation for these buildings is provided via

rudimentary supply and extract wall mounted fans coupled with a gas fired heater located within the

buildings along with localised infra-red heaters in the cages. Home Office regulation for puppies requires a

local environmental temperature of 26-28 Deg C for at least the first 5-10 days of life. It is not clear how

these parameters are being recorded / monitored at site.

DX Systems

The site has a DX system providing heating and cooling for the Archive room, the office block does not

have cooling, with fresh air provided via openable windows.

Boilers

The site has gas fired boilers providing Heating and DHW to the small admin offices located within each

building all across the site. DHW for male and female change areas in some buildings is provided via a

point of use standalone electric water heater.


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Oil Tanks

As the site does not have a mains gas supply, all heating and DHW services are via Oil tanks and LPG tanks

located at the following locations:

During the survey, it was noticed that the LPG tanks had a proper concrete plinth, the oil tank bunding for

the admin block was not compliant with the Oil storage regulations. Failure to comply is a criminal

offence. The site could be fined up to 5,000.

DEFRA can serve a notice under section 161A Water Resources Act 1991 (works notice) to make the site

improve the oil storage standards. Failure to comply with a notice is a criminal offence and may result in

prosecution.

Domestic Hot Water Provision

Domestic hot water is provided by gas fired DHWS generators located in various blocks. The hot water is

circulated throughout the building to its points of use. The site has hard water with large calcium

carbonate deposits and has maintained rigorous water softening maintenance policy. It is recommended

that all tanks are de-scaled annually as part of the L8 service.

Lighting

Lighting at site is generally in good order with a combination of Fluorescent T5 light fittings in the barriers,

and office areas. The Lux levels in the office areas were between 380 Lux and 600 Lux in some areas,

which is quite acceptable for an office environment and complies with the CIBSE Lighting Guide (LG7)

regulations, Lighting Guide 7 (2005): Office lighting and the BS EN 12464-1:2002 Light and lighting -

Lighting of work places - Part 1: Indoor work places.

Lighting in the production areas consists of T5 Fluorescent Light fittings. Lux levels measured in the

production areas were within an acceptable range.

We would recommend that the lighting in the offices be integrated with Energy efficient lighting controls

with PIR occupancy switches with daylight linked dimming thereby reducing energy bills further. We

would recommend these lighting controls; they have a simple payback of less than 2 years.

Lighting for the production areas and stores are recommended to be changed from the existing T8

Fluorescent lighting to HF T5 tubes along with intelligent control to take diurnal / seasonal patterns of the

rodents. A lighting survey had been undertaken, the results of the audit have been enclosed as separate

report.


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Building Management Systems

The site does not have a BMS and was found lacking of an effective control strategy at site, it would

appear that only Building 3 is connected on the BMS with out of range alarms with the outstation located

at Hillcrest. Operational problems are being indicated by the site personnel with no means of viewing

control parameters at site, it is highly recommended that the site incorporate a BMS outstation with all

plant operations on a BMS outstation to have effective control of critical monitoring parameters to ensure

HO compliance.

Automated Metering / Monitoring and Targeting

The site does not have adequate sub metering on any buildings, individual auxiliary plant serving the

building do not have a dedicated energy input or hours run meter. Meter readings are read and recorded

on a regular basis and this data was provided by the client prior to attending site. Additionally this setup is

not ideal as it does not reward energy efficiency in anyway.

It is recommended that the scope of metering be reviewed to install appropriate metering at least to the

more significant energy consuming air conditioning plant, and subsequently to record the consumption on

a regular basis.

it is preferable to automate the Utility consumption of major ancillary loads in order to identify individual

energy consumption patterns and thereby seek energy reduction, by various options available to the

client which include installation of AMR (Automated Meter Reading) to capture half hourly Energy

consumption data in order to monitor energy consumption and to gather real time energy profile data as

part of the drive to reduce energy and running costs.

We would recommend that monitoring & targeting system be introduced to the site to allow a more

detailed review of energy use on the site.

A good M&T system would enable the following:

establish current consumption

compare current consumption with historical data and benchmarks

set future targets

compare current consumption with the targets

identify trends in consumption

Produce exception reports when targets are exceeded.

Accurate apportioning of utility costs for the different tenants


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Auxiliary Services

In addition to air conditioning, ventilation, lighting and hot water, the admin building uses electricity for

powering the building IT servers, printers, photocopiers, computer workstations, kitchen and tea room

preparation areas. These Auxiliary services should be switched off when not in use to conserve energy.


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5.0 Documentation, Maintenance, Specific Fan Power & Metering

All documentation required to compile this report was either provided prior to attending site by the

FMT, whilst on site. The following list of documentation was requested during the site inspection:

Operation and Maintenance manuals

Plant Installation drawings

Planned Preventative Maintenance Records

Floor Plans (used for the calculation of ventilation air change rates)

While reviewing the onsite records, there were no Operational and Maintenance manuals,

Commissioning Data for the Mechanical plant including commissioning results ( including flow rates)

for the AHUs, were not found with the O&M Manuals. The As Built record drawings and subsequent

amendments were not available at site, probably due to the fact that there are no records available

at site due to the age of the building. Planned Preventative Maintenance Records indicating the

frequency of maintenance / schedules and building log book were not available during the visit.

It is recommended that the site carry out a complete re-commissioning of all the blocks, in order to

validate air flows, water flows, fan ESPs and ACHP rates across various barriers in the various blocks.

The refrigeration servicing or leakage inspections are being undertaken by an external specialist

contractor. This work however, is regularly undertaken by the sites refrigeration contractor who is

responsible for the upkeep and maintenance of all refrigeration equipment.

The indicated service frequency should comply with normal practice and the recommendations of

HVCA SG20 (Standard Maintenance Specification for Mechanical Services in Buildings - Section 9

Packaged Chillers), Service reports only indicate that work has been untaken and no details of the

content of the service visit i.e. major or minor. A separate service report sheet is recommended to

confirm the detail of the work undertaken.

Duct Cleaning

It would appear that the ductwork serving the Buildings has never been cleaned and disinfected, this

problem is compounded by the fact that there is inadequate levels of air filtration while we would

advise that these systems be periodically cleaned and disinfected to prevent build up of debris, thus

encouraging microbial growth. The client has stated his concern of long downtimes and an increased

exposure for revenue generating processes.


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We would recommend that while the AHUs are being replaced, a temporary Air Sock be installed

which would form part of a standby system and connected to the AHU, while the ductwork is being

cleaned. This would help in minimising downtime.


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7.0 Summary Condition Appraisal and Maintenance Overview

The AHUs serving the building are rudimentary and do not incorporate adequate level of air

filtration in them, the air socks in building 2a was found to be torn, air flow rates of these units are

unknown it is not clear whether current home office regulation of 10-12 ACPH are being achieved.

Some of the AHU fan section had foliage and debris in them indicating no filters were present, a

minimum of F6 level of filtration would be needed to protect the fans and air socks from airborne

dirt and debris.

In general, the majority of plant and equipment is in operation, although a number of issues

observed whilst on site need to be addressed and these are commented on in paragraphs to follow.

Based on the Code of practice as advised by the Home Office for the housing of animals in designated

breeding and supplying establishments which were prepared in consultation with Laboratory Animals

Breeders Association (LABA) Guidelines on the care and housing of animals bred for scientific

purposes, the Association of the British Pharmaceutical Industry (ABPI), British Laboratory Animal

Veterinary Association (BLAVA), Institute of Animal Technology (IAT), and the Laboratory Animal

Science Association (LASA), the ventilation rate of the room is related to stocking density and to the

heat generated by animals and equipment in the room (thermal load).

In order to maintain suitable air quality 10-12 changes of fresh or air conditioned air per hour

distributed throughout the room would normally be adequate for rooms with high stocking densities

eg dogs etc. It is highly recommended that the ventilation system complies with European

regulations Directive 2010/63/EU which will take full effect from 1 January 2013.

At present none of the AHUs are capable of meeting the 15-20 ACHP criteria laid down by the code

of practice.


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Buildings 16,17,18,19,20,21 housing the Whelping puppies, have uncontrolled ventilation provided

via rudimentary supply and extract wall mounted fans coupled with a gas fired heaters along with

localised infra-red heaters in the cages. Home Office regulation for puppies requires a local

environmental temperature of 26-28 Deg C for at least the first 5-10 days of life. It is not clear how

these parameters are being recorded / monitored at site. These buildings do not have any filtration,

thereby rendering all these buildings susceptible to airborne particulate matter / airborne viruses, a

virus strain from the nearby testing facility could wipe out the entire stock of Whelping puppies and

poses a business continuity risk.

We would recommend that all the AHUs at site be either refurbished or replaced by Low Energy

AHUs by incorporating Run Around Coils or heat Pipes to avoid cross contamination between the

Supply and Extract Air streams while still incorporating a Heat recovery module.

Evidence provided at the time of inspection, suggests that a comprehensive planned preventative

maintenance (PPM) regime is needed at site, which includes an effective reactive maintenance

regime supported by onsite maintenance personnel.

Consideration should be given towards providing a BMS system at site. A BMS system would cost

200K to incorporate optimization start up sequencing for the HVAC system. The Budget costs

provided are estimates only. We would advise that should these works be considered, a detailed site

survey be undertaken prior to carrying out the above works.

Filtration

As is evident from the above pictures, it would air filtration at site in nonexistent. As the site

operates an animal research facility with emphasis on breeding pure breeds, we would recommend

that consideration should be made towards setting up a filtration standard at site. It is recommended

that air filtration at site be upgraded to F9 or F13 depending on the level of protection to prevent

airborne viruses / pathogens from contaminating the pure breed being bred at site.

The site does not have extract ductwork which could provide a possible path for airborne viruses and

contaminants to enter site, it is important that the entire ventilation philosophy be reviewed at site.

Specific Fan Power

Whilst on site, power consumed by all large supply and extract fans (including losses through

switchgear VSDs) was measured in order that Specific Fan Power (SFP) of each system may be

determined and compared with current levels recommended in the Non- domestic Heating, Cooling

and Ventilation Compliance Guide.

Specific Fan Power of the AHUs could not be calculated due to lack of data available regarding their

flow rates. The AHUs currently do not meet the required specific fan power detailed in the Non-

domestic Heating, Cooling and Ventilation Compliance Guide. Consideration should be made to


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review the air flow rates by re-visiting the ventilation design and BMS philosophy is also

recommended.

Metering

No individual items of plant serving this building has its own dedicated energy input or hours run

meter. Meter readings are read and recorded on a regular basis and this data was provided by the

client prior to attending site.

It is recommended that the scope of metering be reviewed to install appropriate metering at least to

the more significant energy consuming air conditioning plant, and subsequently to record the

consumption on a regular basis. CIBSE TM39: Building energy metering provides guidance on

developing a metering plan and should be consulted for best practise and advice.

It is also recommended that AMR (Automatic Meter Reading) for all the tenants is introduced, this

would automate the billing process, it also includes trends in consumption etc which would help the

tenant to identify wastage in energy and help reduce energy consumption. As a general rule, a 5%

energy saving is expected by incorporating an AMR.

8.0 Capital Investment Opportunities

AHU Replacement

Due to the fact that the AHUs serving the buildings are more than 30 years old and showing signs of

failure, along with the fact that these AHUs are not capable of providing 15-20 AHCP as mandated by

the European directive which comes into effect in 2013.

There are two options available for review:

A Twin Fan system, operating at 50% duty each, capable of ramping up to design duty during

maintenance of a single system.

Incorporating a Fan Wall Technology system, with a 2N redundant system. The benefits of

Fan Wall Technology include:

o Dramatically Shorter Footprint

o Quiet Operation and Low Vibration

o Optimized Performance and Energy Efficiency by providing more uniform air

velocities across filters and coils.

o Redundancy by Protecting critical assets and minimizing downtime exposure for

revenue generating processes

o Lower Maintenance Costs


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We would estimate a budget cost of 200K for replacing these AHUs.

Building Management System

The site does not have a BMS and was found lacking of an effective control strategy at site, it would

appear that only Building 3 is connected on the BMS with out of range alarms with the outstation

located at Hillcrest. Operational problems are being indicated by the site personnel with no means of

viewing control parameters at site, it is highly recommended that the site incorporate a BMS

outstation with all plant operations on a BMS outstation to have effective control of critical

monitoring parameters to ensure HO compliance. A budget cost for a new BMS would be 200K.

Gas Fired Burners

Operational problems at site indicate a very high frequency of failure of the gas fired heaters,

primarily due to the age of the plant. It is also worth noting that these burners have a poor efficiency

of around 55-60%. It is recommended that these be replaced by energy efficient burners along with an

effective control strategy including weather compensation.

As the site is considering installing cooling to comply with home office regulation, it is therefore

recommended to explore a gas based heat pump solution providing heating and cooling thereby

reducing the need for expensive electrical upgrades to incorporate cooling. personnel with no means

of viewing control parameters at site, it is highly recommended that the site incorporate a BMS

outstation with all plant operations on a BMS outstation to have effective control of critical monitoring

parameters to ensure HO compliance.

We can provide budget costs of a Gas based heat pump once treated floor areas of these buildings are

made available.

Enhanced Capital Allowance (ECA) and funding

Enhanced Capital Allowances (ECAs) enable a business to claim 100% first-year capital allowances on

their spending on qualifying plant and machinery.

There are three schemes for ECA's

Energy saving plant and equipment

Low carbon dioxide emission cars and natural gas and hydrogen fuelling infrastructure

Water conservation plant and machinery.


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Businesses can write off the whole of the capital cost of their investment in these technologies

against their taxable profits of the period during which they make the investment. This can deliver a

helpful cash flow boost and a shortened payback period.

For products on the Energy Technology Product List, a claim can be made on the cost of the

equipment itself, and other costs directly involved in installing it. These include:

Direct Transportation the cost of getting equipment to the site.

Direct Installation cranage (to lift heavy equipment into place), project management costs and

labour, plus any necessary modifications to the site or existing equipment.

Professional Fees if they are directly related to the acquisition and installation of the equipment.

Any remote or indirect costs do not qualify for the ECA for example, staff time spent taken to

select the right equipment. Only new equipment is eligible for an ECA used or second hand

equipment does not qualify.

All the plant selected falls under the Energy Technology product list, there by all the entire project

costs could avail ECA benefit. Details of how to apply for ECA is available on the DECC website, we

can also provide assistance towards applying for ECA benefit.

9.0 Action Plan / Way Forward

Harlan Labs and EECO2 will develop a strategic plan to Identify and prioritise projects, confirm cost

benefits, develop scope and budgets and produce an implementation plan for approval and budget

allocation.


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10. Conclusions

The report highlights the preliminary energy, operational and management issues associated with

Harlan Labs, Wyton. it is advisable that a ventilation and filtration philosophy be incorporated in

order to address business continuity risks and to meet regulatory compliance, it preferable to

automate the Utility consumption of major ancillary loads in order to identify individual energy

consumption patterns and thereby seek energy reduction, by various options available to the client

which include installation of AMR (Automated Meter Reading) to capture half hourly Energy

consumption data in order to monitor energy consumption and to gather real time energy profile

data as part of the drive to reduce energy and running costs. A BMS system for plant automation /

control is preferable to realise energy savings through incorporating energy optimisation schedules.


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11. Sample FRS (Functional Requirement Specification)

Documents

Harlan Labs Wyton HVAC Energy Audit R1