elements of a succesful energy management approach for life sciences industry

Presented by Derek HookBusiness Development Manager

Invensys

Energy Management For The Life Sciences…

What is CEM?

• ‘CEM’ refers to sets of actions that move accountability for energy outcomes to upper levels of the firm.

• With CEM, energy is no longer the sole responsibility of plant managers and engineers. CEM programs are designed to involve many areas of business activity, such as accounting, marketing, and others that were not traditionally concerned with energy.

• Bringing corporate‐level attention and management into the picture helps to ensure enterprise‐wide opportunities are explored.

From US Dept of Energy: http://www1.eere.energy.gov/industry/bestpractices/corporate_energy.html

Definition Of Corporate Energy Management…

• Allocation of energy cost to produced goods and services is not accurate or useful in understanding the true cost of goods sold

• Poor maintenance of equipment and assets causes energy waste

• Operators are not aware of the consequences of decisions that create excessive energy usage or demand

• Self generated energy is difficult to integrate into the operation

• Data for effective energy management is captured in other plant systems not integrated with operations

The ultimate goals are:

• To reduce fuel use• Reduce CO2 emissions• Maximize cumulative avoided energy costs• Accrue recurring annual savings• Improve the overall plant efficiency.

The savings realized will depend upon the nature of the initial conditions, but experience shows energy savings in excess of 10% can be reasonably expected.

Journey: Paved In Awareness…

Ad Hoc


Ad Hoc


Awareness

Ad Hoc


Awareness Managed

Ad Hoc Awareness Managed

The “Low Hanging Fruit” is addressedEnergy efficient lighting, occupancy sensors, remove lightingVariable speed drives installedLow flow water fixtures installed and re‐use of water for boilers, etc.Spot check and manual reporting of energy/water usage monthly or weeklyReduce ‐ steam pressure / dehumidification / air changesImprove insulation on pipes / boilers, etc.

Journey: Starts With Pain & Uncertainty…


The “Low Hanging Fruit” is addressedEnergy efficient lighting, occupancy sensors, remove lightingVariable speed drives installedLow flow water fixtures installed and re‐use of water for boilers, etc.Spot check and manual reporting of energy/water usage monthly or weeklyReduce ‐ steam pressure / dehumidification / air changesImprove insulation on pipes / boilers, etc.

ChallengesDid it work?Is it still working?Which measures undertaken contributed most of the savings?Are there unintended consequences of these measures?What if Roberto leaves?

Journey: Starts With Pain & Uncertainty…


Journey: Pain Gets Paved By Awareness…


The organization learns about energy use and adaptsSub‐metering gives more granular usageExperiments occur… what if we did this..? Kaizen in action!Investments are made knowing ROI can be determinedWeekly, Daily, Shift reports become part of normal operations managementReal‐time notification of success, deviations, failures



The organization learns about energy use and adaptsSub‐metering gives more granular usageExperiments occur… what if we did this..? Kaizen in action!Investments are made knowing ROI can be determinedWeekly, Daily, Shift reports become part of normal operations managementReal‐time notification of success, deviations, failures

ChallengesDemand for more meaningful data, related to what people are responsible forKnowing deviations and failures is good, but can we prevent them? Are there unintended consequences?



Journey: Awareness Leads To Management…


Energy Management is an organizational competency



Energy Management is an organizational competencyEveryone knows how energy usage and deviation effect financial performance



Energy Management is an organizational competencyEveryone knows how energy usage and deviation effect financial performanceEnergy is managed as a variable cost and used by ERP for planning



Energy Management is an organizational competencyEveryone knows how energy usage and deviation effect financial performanceEnergy is managed as a variable cost and used by ERP for planningThe benefits of the energy management are sustained year after year



Energy Management is an organizational competencyEveryone knows how energy usage and deviation effect financial performanceEnergy is managed as a variable cost and used by ERP for planningThe benefits of the energy management are sustained year after yearAutomation is in place to prevent deviations



Energy Management is an organizational competencyEveryone knows how energy usage and deviation effect financial performanceEnergy is managed as a variable cost and used by ERP for planningThe benefits of the energy management are sustained year after yearAutomation is in place to prevent deviationsSmart Grid becomes a competitive advantage, bring it on!




Challenges




ChallengesChange




ChallengesChangeContinuous improvement




ChallengesChangeContinuous improvementAre there unintended consequences?


Automatic•Direct to Meters (also wireless)•Meters thru PLC/DCS•RTU from remote sites•Building Management System•Utility Interval Readings

Mobile•IntelaTrac•Mobile Data Collection

External Context•Weather‐ Current, Forecast•Utility Rates•Demand Response Signals from Grid

Internal Context•Operational Events from automation and MES•Asset State from automation•Order, Batch, SKU

Energy UsageData

Usage Context

Corporate KPI

Asset ManagementCMMS

ERP/MES

Energy Metrics

Work Request

Energy Usage

InTouch HMI•Real‐time view of energy usage•Configuration of the application

Web Portal•Run Pre‐configured reports

Production WorkerLocal

Energy ManagerCorporate

Energy Manager

Energy Information

Advanced Analysis and Simulation

Rich Data

Intelligence•Run Pre‐configured reports•EMI for Operations

Corporate EnergyManagement

Context Transforms Data Into Information…

• A well structured long term plan for continual improvement


• A companywide cultural ownership approach



• An awareness of the importance of sustained cost savings




• Establishment of multi disciplinary teams to implement CEM




• Establishment of multi disciplinary teams to implement CEM

• Integrate these efforts into other corporate improvement programs

• You need an understanding of where you are now in terms of Energy Management


• Establishing a baseline in order to gauge future improvement



• If you cannot measure it you cannot prove it. If you cannot prove it, you cannot define the ROI




• The challenge is to provide the return on investment (ROI) necessary to obtain funding.





• Start slowly but take every opportunity to provide metering capabilities when you make changes





• Start slowly but take every opportunity to provide metering capabilities when you make changes

• In this way you will achieve the necessary metering ‘resolution’ to be able to discern the ‘detail’

• Begin metering and sub‐metering plus ‘virtual’ metering


• Monitor electrical energy, water, air, fuel, and steam



• Correlate this data to the operational phase, batch, location, date and time.




• Produce Key Performance indicators (KPI’s) to report information in context





• Utilize industry available software tools to convert this wealth of information in useful data.






•You can then relate usage to time and location and thereby determine the true ‘Energy Intensity’






•You can then relate usage to time and location and thereby determine the true ‘Energy Intensity’

•‘Energy Intensity’ = energy required per unit production, corrected for location and time of usage.

The Solution Is In Your Hands…

For more information, contact

Invensys Life Sciences Managing Consulting team

Derek Hook : [email protected]

Jonathon Thompson: [email protected]

elements of a succesful energy management approach for life sciences industry

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