GMS Irvine - Energy Efficiency

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1 GMS Irvine - Energy Efficiency GSK Irvine Winner - Low Carbon Award 2013 The European Chemical Industry Council Winner of the 2013 Energy Efficiency Award

GSK High Level Environmental Sustainability

Environmental Strategy 2015 2020 10% reduction

overall Carbon Footprint 20% reduction (Direct

5% Mass efficiency 25% Reduction in Operational

non-hazardous waste 5% Mass efficiency Zero

2 GSK High Level Environmental Sustainability Strategy Carbon Neutral Value Chain by 2050 GSK Environmental Strategy % reduction in overall Carbon Footprint 25% reduction in overall Carbon Footprint 20% reduction (Direct Ops) 20% reduction (Value Chain) 2.5% Mass efficiency 25% Reduction in Operational waste to landfill 25% Reduction in hazardous and non-hazardous waste 5% Mass efficiency Zero Operational waste to landfill 50% Reduction in hazardous and non-hazardous waste

Key GSK Products Supported by Irvine Site Amoxil Augmentin AMOXIL

antibiotic, an analog of ampicillin, with a broad spectrum of

microorganisms AUGMENTIN An oral antibacterial combination consisting

3 Key GSK Products Supported by Irvine Site Amoxil Augmentin AMOXIL Formulations of AMOXIL contain amoxicillin, a semisynthetic antibiotic, an analog of ampicillin, with a broad spectrum of bactericidal activity against many gram-positive and gram-negative microorganisms AUGMENTIN An oral antibacterial combination consisting of the semisynthetic antibiotic amoxicillin and the β-lactamase inhibitor, clavulanate potassium

4 Irvine Energy Consumption vs GMS From 75 GMS Sites, Irvine = 14% of GMS total Energy consumption. Large scale Fermentation & Solvent Recovery Electricity: Agitation, Cooling, Compressed air, HVAC Gas: Solvent Recovery, Sterility, Process heating.

Near/Off-site Renewables Biomass CHP BioGas CHP 120,000,000 2012 CO 2 From Energy (tonnes) On-site Wind

5 GMS Irvine -Sustainable Manufacturing Energy efficiency to Off the Grid. Our ambition of taking Irvine, GSK s largest energy using site, off the grid. Near/Off-site Renewables Biomass CHP BioGas CHP 120,000, CO 2 From Energy (tonnes) On-site Wind Turbine Generators 100,000,000 80,000,000 Energy Efficiency Projects 60,000,000 40,000,000 20,000,000 - Irvine Ulverston Jurong Cork Montrose Quality Road Port Fairy

Energy Efficiency 2009 2012 24% reduction in CO2 from Energy Solvent Recovery Enrgy Savings Department Energy Reports and Focus Teams 25,000 2,000,000 20,000

Oct-11 Nov-11 5,000 Dec-11 2010 Average Monthly Consumption (kwh) 2010 Average SEC (kwh/te) 45,000 40,000 Savings / day Savings / month Savings / year 1,100

21,292 255,500 1,200,000 35,000 650 19,771 237,250 1,000,000 30,000 600 18,250 219,000 800,000 25,000 550 16,729 200,750 500 15,208 182,500 450 13,688 164,250

Energy Savings Accumulator 30,000 Peng Agitation Electricity 2,500,000 SEC (M3/Te) Electricity Consumption (kwh) 3,000,000 10,000 200,000 5,000 - Jan-11

Consumption (kwh) 2010 Average SEC (kwh/te) Dec-11 2011 Agitation Electricity Consumption kwh PenG Clav 2010 Average Agitation Electricity Consumption kwh

Throughput 2011 SEC 2010 SEC SEC % Change vs 2010 300 9,125 109,500 250 7,604 91,250 200 6,083 73,000 150 4,563 54,750 100 3,042 36,500 50 1,521 18,250 - - %

6 Energy Efficiency % reduction in CO2 from Energy Solvent Recovery Enrgy Savings Department Energy Reports and Focus Teams 25,000 2,000,000 20,000 1,500,000 15,000 1,000,000 10, ,000 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug Monthly Consumption (kwh) 2011 Monthly SEC (kwh/te) Oct-11 Nov-11 5,000 Dec Average Monthly Consumption (kwh) 2010 Average SEC (kwh/te) 45,000 40,000 Savings / day Savings / month Savings / year 1,100 33, ,500 1,050 31, ,250 1,000 30, , , , , , , , , , , , , ,500 1,200,000 35, , ,250 1,000,000 30, , , ,000 25, , , , , , , , , , ,750 20, ,000 15, ,000 SEC (M3/Te) Electricity Consumption (kwh) Sep-11 Clav Agitation Electricity 1,400,000 Energy Savings Accumulator 30,000 Peng Agitation Electricity 2,500,000 SEC (M3/Te) Electricity Consumption (kwh) 3,000,000 10, ,000 5,000 - Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul Monthly Consumption (kwh) 2011 Monthly SEC (kwh/te) Aug-11 Sep-11 Oct-11 Nov-11 Dec Monthly Average Consumption (kwh) 2010 Average SEC (kwh/te) Dec Agitation Electricity Consumption kwh PenG Clav 2010 Average Agitation Electricity Consumption kwh 1,974,757 1,609,735 1,076, ,780 20,473,857 19,316,821 10,637,056 10,401,365 % Change vs 2010 (Target= -5%) 2011 Agitation Cost 2011 Production Throughput 2011 SEC 2010 SEC SEC % Change vs , , ,604 91, ,083 73, ,563 54, ,042 36, ,521 18, % Te kwh/te kwh/te 22.7% 24.3% 118, ,947 16,801 64, ,944 21,141 1, ,021 16, ,123 21,141 % 18.7% -5.7% YTD PenG Clav 6.0% 2.3% 1,228, , % -0.1% -

7 What is a Site Energy Kaizen? Structured 5 day event, designed to identify energy saving opportunities, quantify plan and to identify resource & support A focused process that involves all users of energy in identifying energy reductions in their areas of influence requires commitment from site director thro to production operative Identifies all types of energy reduction opportunities from Just Do Its (JDIs) to capital intensive type projects Defines Responsibility and Time Plans Performance measurement using tiered metrics structure energy dashboard Team working, encourages and empowers to achieve site commitment which is retained after the event Collaborative Approach -Kaizen team will provide structured help & assistance

8 Energy Kaizen Agenda Day 1 Day 2 Day 3 Day 4 Day 5 Measure,Assess, Diagnosis Define, Identify Opportunities & Scoping Improve Performance Management Control Quantification & Tracking Kaizen Core Team Preparation Introduction Site & Kaizen 0830 Assess Current State data- Walk the Walls Current Projects Waterfall Review Energy Checklist Gemba Interim Outbrief 0830 HVAC, Quantification, cost, savings, benefits estimation JDI Account abilities Resources Out Brief Preparation Waterfall Diagram preparation Team brief Team brief CHP Key Focus Areas Strategic projects Energy Baseline- Current Waterfall Preparation Partnerships & Projects Support M&T Technique Tiered Metrics & M&T Governance TP13 Building Occupancy Standard work Maintenance 1 Operations 2 Standard Work Review Operations 1 New Projects Review Planning- Waterfall diagram Preparation 1130 Out Brief

9 Kaizen Outputs Project Prob. of Success (0 to 1.0) Benefits realisation from end of TOTAL Revenue (RON) TOTAL Capital Cost (RON) Adjusted Total (kwh) Adjusted CO2 Saving Adjusted Adjusted Cost Saving Payback (RON) (years) CHP Q4 1,029, , , Reduce HVAC during w/e AHU 10 01, 03, 06 + VSD - critical Q2 35, , , AHU 10/02,04, 05 set back out of hours & VSD non critical Q1 35, , , FGW - HVAC "free cooling" (Pilot) Q4 20,000 45, , , Schneider Electrical Survey (HEM/VSDs/Harmonics) Q1 51, ,031 96, , Completion Metering Monitoring & Targeting Task Q4 75, , , Owner 18, Priority Date Summer use excess heat from B10 to pre-heat boiler return Q2 61, , , Sunday electrical usage high - investigate reduction G.Popa 2012 Q2 High Manual hot water Investigate control valves FLT charging - automate during lower tariff times Q4 30, , S.Moroe 16, Q4 High Use small compr.(3kw) Building at 9 W/E - Electrical for Purified water Water heater used for solvent 1 store 2012 heating Q4 - is it required? 14,640 33, M. Tipurita 8, Q4 High Building 14 - re-check temp setpoint against product requirement (try for wider band) S.Moroe/G.Popa 2011 Q4 High Seg. F26 and connect to HV10-02 and low rate at w/e in FG w/h Q4 10,000 50, , Building 11 - re-check temp setpoint against product requirement (try for wider band) S.Moroe/G.Popa 2011 Q4 High Air manager control Building of air 15 compressors - Repair windows that will not close Q4 29,280 32, I.Mindrila 8, Q4 High Monition Thermographic HVAC Use Survey the & control Implementation system to check periodically the operation Q4 39,040 of control 29,280valves 58, E.Hanzi 5, Q2 High Implement SWEEP HVAC / Shutdown - Make sure / Start-up cooling and heating coils are 0.4 not fighting 2012 Q4 against each other 0 24, G.Popa 6, Q4 High Raise STP for HVAC Pilot- EECO2 S.Moroe 2012 Q1 High Compressed Air Leak Survey & Repairs Q4 9,760 22, , Feasibility for new VSD compressor to replace fixed speed machine S.Moroe 2012 Q1 Medium Building 15 - Reduce Heat from heating air load/ compressor Improve controls to heat technical area 1 in winter 2012 duct Q4 heat out in 4,880 summer 43, T.Timofti 3, Q1 Medium Building 11 - Reduce Investigate heating timed load / main Improve valve controls to isolate air during 1 no production G. Popa 2012 Q4 9,760 38, , Q1 Medium Investigate in summer to use excess heat from Bl 10 to pre-heat boiler combustion air M. Tipurita 2012 Q2 Medium Raise STP for Monition Thermographic Survey S.Moroe 2011 Q4 Medium Produce SWEEP / Shutdown / Startup plans for each area P.Sava/A.Toma 2012 Q2 Medium Investigate hot water solar panels for washing area M. Tipurita 2012 Q2 Medium Lab project - monitor contractor cabins energy use S.Moroe 2011 Q4 Medium Canteen - heating on window open / lock controls A.Boghiu 2011 Q4 Medium Investigate Ground water precooling for Purified water plant G.Popa 2012 Q1 Medium Compressed Air Drying for wash area : alternative? G.Popa/P.Sava 2012 Q2 Medium Building 15 - Close windows when heating is on C.Ghiorghitoiu 2011 Q4 Medium Building 11 - Fit extract fan in toilets to avoid window being opened A.Agapie 2011 Q4 Medium Building 11 - Close windows when heating is on A.Mitelut 2011 Q4 Medium List of Projects by CO 2 Saving. List of JDI s & Investigations. Developed into annual Performance targets Site commitment to resource & fund projects.

Irvine Site Energy Performance & Project Management Irvine Tiered Performance Review Process Energy and Sustainability Hourly Shift Daily Weekly Monthly Quarterly Divisional PPO

Energy Focus Teams Visual Control board(weekly & Monthly) SM Board Meeting Performance and Projects Slide Pack Conference Room TIP0 Progress Update Telecall Team Leaders

10 Irvine Site Energy Performance & Project Management Irvine Tiered Performance Review Process Energy and Sustainability Hourly Shift Daily Weekly Monthly Quarterly Divisional PPO Sustainability Council Site Leadership Dept. Energy Focus Teams Visual Control board(weekly & Monthly) SM Board Meeting Performance and Projects Slide Pack Conference Room TIP0 Progress Update Telecall Team Leaders Performance Management ( Daily 9 am) Local Value Stream Boards Dept. Walls Conference Room 90 day Closeout Day personnel Shift handover meeting (7am, 3pm,11pm) Local Control, Status Boards Dept. Walls Poster Operators Local Control boards, Visual tracker, SWI Local Control, Status boards Energy Centre Energy Centre

11 Site Energy (CO 2 ) Monitoring 2013 YE forecast = 7 % reduction in CO 2 per MT of Product (YTD actual + Nov estimate)

GMS Irvine -Sustainable Manufacturing Energy efficiency to Off the Grid. Our ambition of taking Irvine, GSK s largest energy using site, off the grid.

12 GMS Irvine -Sustainable Manufacturing Energy efficiency to Off the Grid. Our ambition of taking Irvine, GSK s largest energy using site, off the grid. BioGas CHP Biomass CHP Near/Offsite Renewables 120,000, CO 2 From Energy (tonnes) On-site Wind Turbine Generators Energy Efficiency Projects 100,000,000 80,000,000 60,000,000 40,000,000 20,000,000 - Irvine Ulverston Jurong Cork Montrose Quality Road Port Fairy

13 Wind Turbine Overview Consented Deferred Planned 4 x 2.5MW Onsite Turbines, (+2 Near site) 65 m to hub, 110 m to blade tip, Expected yield 6GWh pa from each WTG

14 WWTP Biogas Project (IV1174) Ref Poster The Anaerobic Digestion Plant will : Reduce COD from our effluent by 50%. Produce 8 GWh of renewable power. Save 3,500 tonnes of CO 2. Provide a cost save 1.4M p.a. by: Offsetting imported power. Providing Renewable incentives. Enable Water Reduction opportunities

(IV1442) Progressing activity towards a detailed feasibility study : Team supporting detailed feasibility study Issued RFQ - by Aug 13. Detailed concept study complete Oct 13.

15 (IV1442) Progressing activity towards a detailed feasibility study : Team supporting detailed feasibility study Issued RFQ - by Aug 13. Detailed concept study complete Oct 13. Appointment of Preferred Bidder - Dec 13. PiP developed and submitted - by April 14. Build/Commission by April 17. Options being considered: 2.5 MWe Backpressure Turbine 20 MWe condensing steam Turbine Limited by Legislation on Steam use (CHPQA)

Overview of `OFF THE GRID` Activity Gas offset by biomass (CHP remains) 156,867,470 KWh Req Thermal Site Power Demand (2016) 208,205,784 KWh Req Output 2010 2011 2012 2013 2014 2015 2016 2017 Output

16 Overview of `OFF THE GRID` Activity Gas offset by biomass (CHP remains) 156,867,470 KWh Req Thermal Site Power Demand (2016) 208,205,784 KWh Req Output Output KWht % of Site % Site Yield No MWe Installation Electricity (KWhe) Demand Req MWt Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 96% On Site NG CHP (Low Carbon) 33,638, % Q3 29% st On Site Wind Turbine 6,438, % Q3 29% nd On Site Wind Turbine 6,438, % Q2 29% rd On Site Wind Turbine 6,438, % 113% Q2 29% th On Site Wind Turbine 6,438, % Q2 93% On Site BioGas CHP 8,146, % Q2 Q3 96% On Site BioMass CHP 168,000, % ,200,000 Q1 29% Near Site Wind Turbines 12,702, % 6.1% Q2 Gap/Export - 40,035, % 100% Total Site Generation 248,241, % 100% 95% 90% 80% 70% 60% 55% 50% 45% 39% 40% 35% 26% 30% 25% 19% 20% 16% 15% 10% 5% Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q

GSK Cork. Global Energy Management System Implementation: Case Study. Ireland. Business Case for Energy Management. Case Study Snapshot

GSK Cork. Global Energy Management System Implementation: Case Study. Ireland. Business Case for Energy Management. Case Study Snapshot Global Energy Management System Implementation: Case Study GSK Cork Through the implementation of a structured EnMS and a culture of continuous improvement, GSK Cork has achieved significant energy, CO