Case Study - HVAC Energy Savings delivered by optimisation of the dehumidification system

Energy Efficiency Case StudyHVAC Energy Savings delivered by optimisationof the dehumidification systemwww.eeco2.co.ukThe project:Potential energy savings associated with humidity control were identified during a site energy audit. Imaichi was selected as the key installation base for the Japan off the grid sustainability initiative, with the target of the pharmaceutical manufacturer’s operations in Japan being carbon neutral by 2015. As a prerequisite in the development of the integrated sustainability plan it was recognised that the energy usage base load should be minimised. In order to progress the energy reduction programme a HVAC pilot project was identified with the following objectives:1 To reduce HVAC energy consumption whilst having no adverse effect on product quality or safety.2 To modify the production area air handling units plus the associated fresh air treatment AHUs during the site summer shutdown in the time allowed.3 To ensure that the savings identified were both viable and deliverable.4 To pass on the experience of the pharmaceutical manufacturer’s sustainability team to the site team such that they could continue to self-deliver further energy reductions in the future.Project challenges:Most of the HVAC systems in the OSD area had been designed to deliver air with very low relative humidity (RH) (less than 35% RH). The current products manufactured require air to be delivered at less than 60% RH. This means that the systems are using much more energy than required to meet these conditions. The HVAC system needed be modified to meet current manufacturing requirements. The system needed to be rebalanced in-line with current guidelines. All without impacting on product quality or manufacturing output i.e. completing and commissioning the systems and revalidating the areas in the timescale available.From the project inception this was the team’s core focus. A product quality risk assessment was developed with the site quality, production and engineering teams. The potential risks were therefore mitigated and incorporated into the design and commissioning procedures.Solution:The desiccant dehumidifier, on the fresh air serving the OSD Area was fitted with an automated bypass, such that when desiccant dehumidification was not required the dehumidifier would be switched off and air bypassed directly to the area recirculation AHU.Client: Location: Site: Date: Sector: Global Pharmaceutical Manufacturer Japan Japan, Utsumoia Q3 2012 Pharmaceutical/Life SciencesIf there was ever a requirement for desiccant dehumidification during extreme ambient conditions, then the dehumidifier is available for use under the control of the Building Management System (BMS). This was modified in line with the requirements of the revised BMS FDS that was prepared for the project. If a future product requires different humidity conditions then the parameters in the control system can be changed accordingly. The airflows were re-balanced in-line with the current Regulatory guidelines.Outcome:The pilot project successfully delivered the expected savings during the 2012 summer shutdown. Working closely with the offsite team has enabled the site team to identify and understand the challenges, scope of work and risk based approach to replicate this on othersimilar systems.Next Steps:Following the successful completion of the pilot project the next three phases are being prioritised and developed for implementation over the next two years to support the master sustainability plan.The total estimated energy savings from all four phases have been projected to be:• 3,400,000 kWh• 660 tonnes of CO2“Thanks to support from theSustainability team and ECCO2,we successfully implemented the project and we have achieved theexpected target. This is a really good show case of saving energy; we will extend the same approach to the other OSD HVAC systems.” Engineering Manager - JapanGENERAL ENQUIRIES & SALESTel: +44 (0) 1625 660 717 Email: info@eeco2.co.ukTECHNICAL SUPPORTTel: +44 (0) 1625 660 717 Email: info@eeco2.co.ukEEC02 LimitedSuite 9, The Green, Fountain Street,Macclesfield, Cheshire, SK10 1JNinfo@eeco2.co.ukwww.eeco2.co.ukFor further information:EEC02 Energy Efficiency Services Pharmaceutical Energy Services 3Energy Monitoring Services 3Project Management 3Energy Consultancy 3EPBD Compliance Sustainability & Renewable Solutions 3Benefits Delivered: • Energy savings delivered 1,165,336 kWh/pa• Energy cost savings £57,006 /pa• Emissions reduction 233 tonnes CO2• Simple pay back 18 months