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Pharmaceutical Industry
Background
- Reduced energy usage.
- Improved operational performance providing improved product quality.
Implementation
- Room differential pressures
- Room temperatures
- Room Humidity
- AHU Air Flow
- AHU Power absorbed
- Cleaning of the units
- Removal of the existing variable speed drive element
- Checking of motor and fan bearings (items replaced as necessary)
- Re-coupling of the motor to the fan (belt drive)
- Re-configuration of the power supplies
- Re-configuration of the control system and philosophy
- Installation of Danfoss IP54 rated Variable Speed Drive Units
- Re-commissioning of electrical systems
- Re-commissioning of control systems
- Re-balancing of air volumes
- Updating of existing O&M manuals
The Results
Pharmaceutical Industry
This paper provides a brief description and overview of the implementation of a Building Management System (BMS) including Monitoring & Targeting at a Large Multi National Pharmaceutical Manufacturer in the North East of England.
Background
The Pharmaceutical Manufacturer is a producer of final product over the counter and prescription medicines. The processes involved are the purchase of raw active and bulk inactive materials used to produce mainly tablet form medicines.
The powder materials are mixed, granulated, fluid bed dried, compressed or encapsulated into tablet form and packaged mainly in blister foil or plastic bottles.
The BMS was a Landis & Gyr standard system used across approximately 25% of the plant. The system was developed and expanded to provide control to a large chilled water systems, production air handling units, office air handling units and the implementation of a Monitoring & Targeting System covering Electrical, Water and Natural Gas.
Implementation
The driving force for the implementation of the M&T system was to enable automatic meter reading on the plant and identification of poor utility usage. Before implementation water leakage on the plant was excessive no energy measurement was undertaken i.e. Degree day performance, batch analysis, etc.
The BMS system was instrumental in reducing the operating cost on the plant by:
- Optimising the start of non critical plant.
- Managing the balance of running hours across the plant.
- Providing monitoring & targeting information enabling management decisions to be made that could prioritise saving opportunities.
- Providing closer control thereby reducing energy usage
- Identifying utility leakage, especially water
The Results
The results of the project were extremely positive and can be summarised as follows:
- Water consumption on the plant was reduced by 50%.
- Energy consumption was reduced by 10% amounting to 600000 kWh/yr of electricity
- Maintenance costs were reduced on this area of the plant.
- Labour efficiency was increased by reducing the menial task of meter reading collection
Chemical Industry
This paper provides a brief description and overview of the implementation of a replacement process cooling water system (PCW) at a Large Multi National Semiconductor Manufacturer in Scotland.
Background
The Semiconductor Manufacture is a producer of microelectronic chips used throughout the world in personal computers and Ipods. The processes involved are the use of a number of ultra pure chemicals and gases.
The PCW system was used to cool over 200 process tools with a value in excess of £200 million.
The existing system was over 20 yrs old and due to production expansion the system was running at full capacity. A number of failures on the plant have cost in excess of £0.5 million in lost production and damaged product.
Implementation
The driving force for the implementation of the PCW system was an need to expand capacity, increasing operational performance and improving energy efficiency across the whole system.
The design undertaken incorporated a number of energy and performance related initiatives including:
- Efficient duty point of pump selection
- High efficiency motors
- Variable speed drive
- Close operational control
- Full plant operation upon control failure, without system issues
- 100% fully redundant system design.
The Results
The results of the project were extremely positive and can be summarised as follows:
- 100% uptime of the system
- Energy consumption was reduced by 5% amounting to 250,000 kWh/yr of electricity
- Maintenance costs were reduced on this area of the plant.
- Labour efficiency was increased by reducing the menial task of meter reading collection
