Pharmaceutical Sustainability Initiatives

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1 Pharmaceutical Sustainability Initiatives Duane Hagen, CEA Energy and Systems Optimization Steam and Condensate System Specialist Technical Training Instructor

2 Primary Energy Sources Conversion of Energy

3 Defining Sustainability The capacity or ability to endure. The long term maintenance of well being that includes; Environmental Economic Societal In energy management the challenge is assessing how can the organization make the best use of its available resources and from this assessment develop action plans that maximizes the sustainability of energy using equipment while controlling costs.

4 Who s Directing Sustainability?

5 A Hagenism on Energy Optimization If you can t change what you pay for fuel, you should be wise enough to change how much fuel you use. Therefore you must know what that usage is and optimize the performance of energy using systems.

6 Energy and Utility System Optimization Project Goals 1. Determine the Existing Conditions. 2. Define the Proposed Conditions. 3. Subtract the Second from the First. Of Critical Importance: Defining the Existing Conditions

7 System Optimization Guidelines Design Implement Sustain Sustainability is the key to success.

9 A Hagenism on The Value of Metering When pursuing energy efficiency what we don t know we can t control. What we can control we can optimize. What we can optimize we can realize as an ROI.

10 kwh Demand 35 kv Main Meter Demand Trending Understanding Your Facilities Energy Load Language

Tracking and Trending for Cause and Effect Day Time Dew Pt Humidity Dry Bulb Wet Bulb Demand kw Total kwh Energy kwh 15-min 6/21/2011 15:45:00 76.82 62.39 92.15 80.52 6,681.00 129,680.34 1,668.

11 Tracking and Trending for Cause and Effect Day Time Dew Pt Humidity Dry Bulb Wet Bulb Demand kw Total kwh Energy kwh 15-min 6/21/ :45: , , , Allow the Data to Lead the Sustainability Discussion How can the Energy Team communicate effectively the importance of load reduction? What can be done to hold the HPD below 7000 kwh during this cooling season? Are all unoccupied areas and equipment that are non-essential powered down? Are the chillers, pumps and towers operating at maximum efficiency? What cost effective improvements can be made to increase efficiency?

3-year MMBtu Usage for 1 Million Square Feet of Facility Linear Regression Analysis Data 2008 kwh 2009 kwh 2010 kwh Month # of Days Average CDD 3-yr Av.

6129 March 31 2,110,500 2,079,000 2,037,000 April 30 42 70,855.5556 April 30 2,107,000 2,068,500 2,201,500 May 31 157 76,698.9247 May 31 2,110,500 2,373,000 2,649,500 June 30 371 101,227.

12 3-year MMBtu Usage for 1 Million Square Feet of Facility Linear Regression Analysis Data 2008 kwh 2009 kwh 2010 kwh Month # of Days Average CDD 3-yr Av. kwh/day Month # of Days Actual Actual Actual January , January 31 2,219,000 2,257,500 2,100,000 February , February 28 1,932,000 1,921,500 2,450,000 March , March 31 2,110,500 2,079,000 2,037,000 April , April 30 2,107,000 2,068,500 2,201,500 May , May 31 2,110,500 2,373,000 2,649,500 June , June 30 2,856,000 2,985,500 3,269,000 July , July 31 3,643,500 3,110,000 3,818,500 August , August 31 3,230,500 3,115,000 3,692,500 September , September 30 3,066,000 2,919,000 2,723,000 October , October 31 2,842,000 2,121,000 2,313,500 November , November 30 2,285,500 2,016,000 1,893,500 December , December 31 2,110,500 2,138,500 1,865,500 Baseload Multiplier Cost/kWh kwh= ((multiplier*average CDD) + Baseload kwh) * Days in Month kwh= ((83.762* Average CDD) + 69,307 kwh) * Days in Month

13 2011 Electric Utility Summary Month Acutal kwh Usage 2011 AEP LPT Actual Billing Charge Projected kwh Usage Projected $.07 Difference Between Projected and Acutal Usage Cost Difference Between Projected and Actual 2110 kwh Usage 2010 Actual Cost January 1,865,500 $107, ,148,842 $150, ,342 $42, ,100,000 $109, February 1,645,000 $102, ,940,596 $135, ,596 $33, ,009,000 $127, March 1,823,500 $109, ,169,290 $151, ,790 $41, ,037,000 $112, April 1,855,000 $130, ,184,750 $152, ,750 $22, ,201,500 $121, May 2,565,500 $186, ,556,187 $178, ,313 -$7, ,649,500 $150, June 2,996,000 $219, ,011,481 $210, ,481 -$8, ,269,000 $178, July 3,552,500 $185, ,511,744 $245, ,756 $59, ,818,500 $214, August 3,262,000 $223, ,415,669 $239, ,669 $15, ,692,500 $243, September 2,750,144 $192, ,723,000 $187, October 2,301,718 $161, ,313,500 $156, November 2,089,733 $146, ,893,500 $137, December 2,150,464 $150, ,914,500 $111, Totals 19,565,000 $1,265, ,230,616 $2,116, ,373,557 $199, ,621,500 $1,851,106.65

14 2011 Electric Utility Summary Month Acutal kwh Usage 2011 AEP LPT Actual Billing Charge Projected kwh Usage Projected Cost at Budgetary Pricing Difference Between Projected and Acutal Usage Difference Between Projected and Actual Cost 3-yr Average kwh Usage 3-yr Average Cost at Budgetary Pricing January 1,865,500 $107, ,148,842 $150, ,342 $42, ,192,167 $153, February 1,645,000 $102, ,940,596 $135, ,596 $33, ,101,167 $147, March 1,823,500 $109, ,169,290 $151, ,790 $41, ,075,500 $145, April 1,855,000 $130, ,184,750 $152, ,750 $22, ,125,667 $148, May 2,565,500 $186, ,556,187 $178, ,313 -$7, ,377,667 $166, June 2,996,000 $219, ,011,481 $210, ,481 -$8, ,036,833 $212, July 3,552,500 $185, ,511,744 $245, ,756 $59, ,524,000 $246, August 3,262,000 $223, ,415,669 $239, ,669 $15, ,346,000 $234, September 2,750,144 $192, ,902,667 $203, October 2,301,718 $161, ,425,500 $169, November 2,089,733 $146, ,065,000 $144, December 2,150,464 $150, ,038,167 $142, Totals 19,565,000 $1,265, ,230,616 $2,116, ,373,557 $199, ,210,333 $2,114,723.33

15 2011 Electric Utility Summary

16 2011 Electric Utility Summary

17 3-year MMBtu Usage for 1 Million Square Feet of Facility Linear Regression Analysis Data 2008 MMBtu 2009 MMBtu 2010 MMBtu MMBtu Month # of Days Actual Actual Actual Month # of Days Average HDD 3-yr Av./Day January 31 37,353 42,120 37,672 January ,260 Febuary 28 40,618 30,027 33,303 Febuary ,237 March 31 35,596 30,196 28,848 March ,018 April 30 22,919 23,291 19,533 April May 31 20,232 16,998 14,507 May June 30 12,875 13,719 14,814 June July 31 14,016 12,962 11,789 July August 31 12,359 11,301 13,118 August September 30 14,361 13,421 15,025 September October 31 23,159 19,624 19,487 October November 30 24,766 22,174 28,414 November December 31 40,817 39,242 35,452 December ,242 MMBtu= ((multiplier* Average HDD) + Baseload MMBtu) * Days in Month Baseload Multiplier 1st Quarter Only Cost/MMBtu MMBtu= ((.8949* Average HDD) MMBtu) * Days in Month $5.00 $5.50

18 2011 Natural Gas Utility Summary Month 2011 Acutal MMBtu Usage Actual Cost Projected MMBtu Usage Projected Cost Difference Between Projected and Acutal Usage Cost Difference Between Projected and Actual 2010 Acutal MMBtu Usage 2010 Actual MMBtu Cost January 37,271 $186, ,831 $214, ,560 $27, ,672 $316, Febuary 30,671 $153, ,417 $167, ,746 $13, ,303 $280, March 28,823 $144, ,436 $167, ,613 $23, ,848 $242, April 20,226 $111, ,795 $119, ,569 $8, ,533 $164, May 18,371 $101, ,711 $97, ($3,627.72) 14,507 $122, June 15,982 $87, ,446 $79, , ($8,445.64) 14,814 $124, July 10,284 $56, ,268 $83, , $27, ,789 $99, August 12,398 $68, ,316 $84, , $16, ,118 $110, September 15,041 $82, ,025 $126, October 21,164 $116, ,487 $163, November 27,190 $149, ,414 $239, December 38,538 $211, ,452 $298, Totals 174,026 $908, ,154 $1,574, ,195 $104, ,962 $2,288,422.87

19 2011 Natural Gas Utility Summary 2011 Acutal MMBtu Usage Difference Between Projected and Acutal Usage Cost Difference Between Projected and Actual 3-yr Average MMBtu Budgeted Cost 2011 Actual Projected 3-yr Average Month Cost MMBtu Usage Projected Cost MMBtu Usage January 37,271 $186, ,831 $214, ,560 $27, ,048 $195, Febuary 30,671 $153, ,417 $167, ,746 $13, ,649 $173, March 28,823 $144, ,436 $167, ,613 $23, ,547 $157, April 20,226 $111, ,795 $119, ,569 $8, ,914 $120, May 18,371 $101, ,711 $97, ($3,627.72) 17,246 $94, June 15,982 $87, ,446 $79, ,536 ($8,445.64) 13,803 $75, July 10,284 $56, ,268 $83, ,984 $27, ,922 $71, August 12,398 $68, ,316 $84, ,918 $16, ,259 $67, September 15,041 $82, ,269 $78, October 21,164 $116, ,757 $114, November 27,190 $149, ,118 $138, December 38,538 $211, ,504 $211, Totals 174,026 $908, ,154 $1,574, ,195 $104, ,036 $1,498,575.83

20 2011 Natural Gas Utility Summary

21 2011 Natural Gas Utility Summary

22 Utilize the Tools to Determine Energy Problems

23 TOC 2 2 nd Floor Dept. 420 Condensate Recovery System Armstrong M10/250 Traps 879 to 881

24 TOC 2 2 nd Floor Dept. 421 Condensate Recovery System Armstrong M10/250 Traps 882 to 883

into this large pumping system for return to TOC boiler plant on

25 TOC 2 2 nd Floor Room A-343 Condensate Pumping System Both condensate recovery systems in departments 420 and 421 discharge into this large pumping system for return to TOC boiler plant on the 3 rd floor. This should be evaluated as part of the water hammer issues.

Reducing the Back Pressure on the Condensate Return System The steam traps that are blowing thru and leaking by are creating issues with over pressurization and replacing these failed traps will

26 Reducing the Back Pressure on the Condensate Return System The steam traps that are blowing thru and leaking by are creating issues with over pressurization and replacing these failed traps will assist in reducing this back pressure some what. The bigger issue is system piping design that creates high pressure return zones that do not allow for the dryer coils, kettles and heat exchangers to free drain. This causes these system to operate flooded and this forces the control valves on these systems to operate at higher pressures than should be required to achieve thermal transfer. All of this is forcing the system to use more energy as it must operate at higher pressure. The results of the steam trap audit has yielded the following:

27 The True Cost of Steam

28 Tracking Cost Trends

29 Water Usage and Waste Water Treatment Water Factoids: 120 drops = 5mL 1 gallon = 3785 ml There are 90,840 Drops in 1 Gallon If a faucet dripped once a second how many gallons of water would it waste/year? 1 year ~ 31,536,000 seconds and 24 drops in 1 ml, thus 1 gallon/3785 ml x (1 ml/24 drops) x (1 drop/ 1 s) x (31,536,000 s/ 1 year) = gallons/year

31 2008 to Present Water Cost to V of M (Less Service Fees) Month 2008 Gallons 2009 Gallons 2010 Gallons 2011 Gallons Jan $36, $25, $24, $24, Feb $29, $19, $23, $18, Mar $26, $28, $28, $19, Apr $33, $31, $27, $21, May $38, $30, $26, $33, Jun $41, $39, $38, $38, Jul $39, $34, $40, $44, Aug $42, $32, $39, $44, Sep $45, $32, $37, Oct $31, $23, $33, Nov $26, $22, $33, Dec $26, $24, $27, Total Usage $418, $344, $378, $246, Water Charge Rate $ per gallon

2008 to Present Waste Water Cost to V of M (Less Service Fees) Month 2008 Gallons 2009 Gallons 2010 Gallons 2011 Gallons Jan $40,060.14 $27,532.07 $26,736.86 $26,938.01 Feb $32,742.75 $21,253.

32 2008 to Present Waste Water Cost to V of M (Less Service Fees) Month 2008 Gallons 2009 Gallons 2010 Gallons 2011 Gallons Jan $40, $27, $26, $26, Feb $32, $21, $25, $20, Mar $29, $31, $31, $21, Apr $36, $32, $27, $22, May $40, $27, $25, $29, Jun $43, $24, $29, $30, Jul $40, $26, $27, $32, Aug $42, $23, $26, $34, Sep $45, $25, $25, Oct $33, $23, $31, Nov $29, $24, $27, Dec $29, $26, $25, Total Output $444, $315, $328, $218, Village Sewer Charge Rate: $ per gallon

Sustainability in Waste Water Reduction Cooling Tower Evaporation Rate versus Sewered Blow Down Metering Savings Analysis Month-2010 Incoming Gallons Sewered Blow Down Gallons Difference Savings

33 Sustainability in Waste Water Reduction Cooling Tower Evaporation Rate versus Sewered Blow Down Metering Savings Analysis Month-2010 Incoming Gallons Sewered Blow Down Gallons Difference Savings January $0.00 February $0.00 March 124,000 14, ,600 $ April 657,000 92, ,600 $2, May 1,114, , ,500 $3, June 3,175, ,700 2,426,300 $10, July 3,776, ,100 2,915,900 $13, August 3,687, ,800 2,760,200 $12, September 1,848, ,000 1,447,000 $6, October 820, , ,900 $3, November 341,000 22, ,600 $1, December $0.00 Total: 15,418,000 3,446,400 12,095,600 $53, Sustainability = Green

34 Improving Efficiency and Reducing Costs

35 A Hagenism on the Basics of WWT It always flows downhill and if it stinks don t eat it.

36 Alternatives in Energy Sustainability

37 Carpe diem Latin Enjoy the day; Seize today's opportunities; Literally - Seize the day.

BEYOND O&M. Shawn Maurer SEDAC Building Energy Specialist. Smart Energy Design Assistance Center (SEDAC), University of Illinois at Urbana Champaign

BEYOND O&M. Shawn Maurer SEDAC Building Energy Specialist. Smart Energy Design Assistance Center (SEDAC), University of Illinois at Urbana Champaign BEYOND O&M Shawn Maurer SEDAC Building Specialist Smart Design Assistance Center (SEDAC), University of Illinois at Urbana Champaign PRESENTATION OVERVIEW and Take away: Regular costs less over the long