Pharmaceutical Sustainability Initiatives

Duane Hagen, CEA

Energy and Systems Optimization

Steam and Condensate System Specialist

Technical Training Instructor

Conversion of Energy

Primary Energy Sources

The capacity or ability to endure.

Defining Sustainability

The long term maintenance of well being that includes; Environmental Economic Societal

In energy management the challenge is assessing how can theorganization 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.

Who’s Directing Sustainability?

A Hagenism onEnergy 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.”

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

System Optimization Guidelines

Sustain

Implement

Design

Sustainability is the key to success.

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.”

35 kV Main Meter Demand Trending

Understanding Your Facilities Energy Load Language

kWh

Dem

and

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 1,668.96

Tracking and Trending for Cause and Effect

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. kWh/Day

Month # of Days Actual Actual Actual January 31 0 70,715.0538

January 31 2,219,000 2,257,500 2,100,000 February 28 0 75,041.6667

February 28 1,932,000 1,921,500 2,450,000 March 31 8 66,951.6129

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 30 371 101,227.7778

June 30 2,856,000 2,985,500 3,269,000 July 31 525 113,677.4194

July 31 3,643,500 3,110,000 3,818,500 August 31 488 107,935.4839

August 31 3,230,500 3,115,000 3,692,500 September 30 267 96,755.5556

September 30 3,066,000 2,919,000 2,723,000 October 31 59 78,241.9355

October 31 2,842,000 2,121,000 2,313,500 November 30 4 68,833.3333

November 30 2,285,500 2,016,000 1,893,500 December 31 1 65,747.3118

December 31 2,110,500 2,138,500 1,865,500

Baseload Multiplier Cost/kWh kWh= ((multiplier*Average CDD) + Baseload kWh) * Days in Month

69307 83.762 0.07 kWh= ((83.762* Average CDD) + 69,307 kWh) * Days in Month

2011 Electric Utility Summary

MonthAcutal kWh

Usage

2011 AEP LPT Actual Billing

ChargeProjected kWh

UsageProjected Cost @

$.07

Difference Between

Projected and Acutal Usage

Cost Difference Between Projected

and Actual 2110 kWh Usage 2010 Actual Cost

January 1,865,500 $107,791.82 2,148,842 $150,418.91 283,342 $42,627.09 2,100,000 $109,146.25

February 1,645,000 $102,000.42 1,940,596 $135,841.72 295,596 $33,841.30 2,009,000 $127,556.89

March 1,823,500 $109,853.63 2,169,290 $151,850.30 345,790 $41,996.67 2,037,000 $112,573.37

April 1,855,000 $130,650.18 2,184,750 $152,932.51 329,750 $22,282.33 2,201,500 $121,727.03

May 2,565,500 $186,624.38 2,556,187 $178,933.07 -9,313 -$7,691.31 2,649,500 $150,116.61

June 2,996,000 $219,382.53 3,011,481 $210,803.67 15,481 -$8,578.86 3,269,000 $178,293.43

July 3,552,500 $185,905.59 3,511,744 $245,822.05 -40,756 $59,916.46 3,818,500 $214,212.31

August 3,262,000 $223,780.48 3,415,669 $239,096.80 153,669 $15,316.32 3,692,500 $243,776.35

September 2,750,144 $192,510.05 2,723,000 $187,445.43

October 2,301,718 $161,120.24 2,313,500 $156,889.80

November 2,089,733 $146,281.28 1,893,500 $137,794.03

December 2,150,464 $150,532.51 1,914,500 $111,575.15

Totals 19,565,000 $1,265,989.03 30,230,616 $2,116,143.11 1,373,557 $199,709.99 30,621,500 $1,851,106.65

2011 Electric Utility Summary

MonthAcutal kWh

Usage2011 AEP LPT Actual

Billing ChargeProjected kWh

UsageProjected Cost at Budgetary Pricing

Difference Between

Projected and Acutal Usage

Difference Between Projected and Actual

Cost3-yr Average kWh

Usage

3-yr Average Cost at Budgetary

Pricing

January 1,865,500 $107,791.82 2,148,842 $150,418.91 283,342 $42,627.09 2,192,167 $153,451.67

February 1,645,000 $102,000.42 1,940,596 $135,841.72 295,596 $33,841.30 2,101,167 $147,081.67

March 1,823,500 $109,853.63 2,169,290 $151,850.30 345,790 $41,996.67 2,075,500 $145,285.00

April 1,855,000 $130,650.18 2,184,750 $152,932.51 329,750 $22,282.33 2,125,667 $148,796.67

May 2,565,500 $186,624.38 2,556,187 $178,933.07 -9,313 -$7,691.31 2,377,667 $166,436.67

June 2,996,000 $219,382.53 3,011,481 $210,803.67 15,481 -$8,578.86 3,036,833 $212,578.33

July 3,552,500 $185,905.59 3,511,744 $245,822.05 -40,756 $59,916.46 3,524,000 $246,680.00

August 3,262,000 $223,780.48 3,415,669 $239,096.80 153,669 $15,316.32 3,346,000 $234,220.00

September 2,750,144 $192,510.05 2,902,667 $203,186.67

October 2,301,718 $161,120.24 2,425,500 $169,785.00

November 2,089,733 $146,281.28 2,065,000 $144,550.00

December 2,150,464 $150,532.51 2,038,167 $142,671.67

Totals 19,565,000 $1,265,989.03 30,230,616 $2,116,143.11 1,373,557 $199,709.99 30,210,333 $2,114,723.33

2011 Electric Utility Summary

2011 Electric Utility Summary

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 31 1523 1,260

Febuary 28 40,618 30,027 33,303 Febuary 28 1312 1,237

March 31 35,596 30,196 28,848 March 31 1184 1,018

April 30 22,919 23,291 19,533 April 30 791 730

May 31 20,232 16,998 14,507 May 31 617 556

June 30 12,875 13,719 14,814 June 30 517 460

July 31 14,016 12,962 11,789 July 31 529 417

August 31 12,359 11,301 13,118 August 31 531 395

September 30 14,361 13,421 15,025 September 30 539 476

October 31 23,159 19,624 19,487 October 31 742 670

November 30 24,766 22,174 28,414 November 30 992 837

December 31 40,817 39,242 35,452 December 31 1368 1,242

MMBtu= ((multiplier* Average HDD) + Baseload MMBtu) * Days in Month Baseload Multiplier 1st Quarter Only Cost/MMBtu

MMBtu= ((.8949* Average HDD) + 18.944 MMBtu) * Days in Month 18.944 0.8949 $5.00 $5.50

2011 Natural Gas Utility Summary

Month2011 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 $186,355.00 42,831 $214,153.90 5,560 $27,798.90 37,672 $316,990.85

Febuary 30,671 $153,355.00 33,417 $167,085.86 2,746 $13,730.86 33,303 $280,227.92

March 28,823 $144,115.00 33,436 $167,177.62 4,613 $23,062.62 28,848 $242,741.35

April 20,226 $111,243.00 21,795 $119,874.41 1,569 $8,631.41 19,533 $164,360.33

May 18,371 $101,040.50 17,711 $97,412.78 -660 ($3,627.72) 14,507 $122,069.08

June 15,982 $87,901.00 14,446 $79,455.36 -1,535.57 ($8,445.64) 14,814 $124,652.33

July 10,284 $56,562.00 15,268 $83,975.53 4,984.28 $27,413.53 11,789 $99,198.48

August 12,398 $68,189.00 15,316 $84,240.00 2,918.36 $16,051.00 13,118 $110,381.34

September 15,041 $82,723.54 15,025 $126,427.79

October 21,164 $116,403.96 19,487 $163,973.26

November 27,190 $149,543.93 28,414 $239,089.46

December 38,538 $211,960.01 35,452 $298,310.67

Totals 174,026 $908,760.50 296,154 $1,574,006.88 20,195 $104,614.95 271,962 $2,288,422.87

2011 Natural Gas Utility Summary

Month

2011 Acutal

MMBtu

Usage

2011 Actual

Cost

Projected

MMBtu Usage Projected Cost

Difference

Between

Projected and

Acutal Usage

Cost

Difference

Between

Projected and

Actual

3-yr Average

MMBtu Usage

3-yr Average

MMBtu

Budgeted Cost

January 37,271 $186,355.00 42,831 $214,153.90 5,560 $27,798.90 39,048 $195,241.67

Febuary 30,671 $153,355.00 33,417 $167,085.86 2,746 $13,730.86 34,649 $173,246.67

March 28,823 $144,115.00 33,436 $167,177.62 4,613 $23,062.62 31,547 $157,733.33

April 20,226 $111,243.00 21,795 $119,874.41 1,569 $8,631.41 21,914 $120,528.83

May 18,371 $101,040.50 17,711 $97,412.78 -660 ($3,627.72) 17,246 $94,851.17

June 15,982 $87,901.00 14,446 $79,455.36 -1,536 ($8,445.64) 13,803 $75,914.67

July 10,284 $56,562.00 15,268 $83,975.53 4,984 $27,413.53 12,922 $71,072.83

August 12,398 $68,189.00 15,316 $84,240.00 2,918 $16,051.00 12,259 $67,426.33

September 15,041 $82,723.54 14,269 $78,479.50

October 21,164 $116,403.96 20,757 $114,161.67

November 27,190 $149,543.93 25,118 $138,149.00

December 38,538 $211,960.01 38,504 $211,770.17

Totals 174,026 $908,760.50 296,154 $1,574,006.88 20,195 $104,614.95 282,036 $1,498,575.83

2011 Natural Gas Utility Summary

2011 Natural Gas Utility Summary

Utilize the Tools to Determine Energy Problems

TOC 2 2nd Floor Dept. 420 Condensate Recovery System

Armstrong M10/250 Traps 879 to 881

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

TOC 2 2nd 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 3rd 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 withover pressurization and replacing these failed traps will assist in reducing thisback pressure some what. The bigger issue is system piping design that createshigh pressure return zones that do not allow for the dryer coils, kettles andheat exchangers to free drain. This causes these system to operate flooded and this forces the control valves on these systems to operate at higher pressuresthan should be required to achieve thermal transfer. All of this is forcing the systemto use more energy as it must operate at higher pressure.

The results of the steam trap audit has yielded the following:

The True Cost of Steam

Tracking Cost Trends

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, thus1 gallon/3785 mL x (1 mL/24 drops) x (1 drop/ 1 s) x (31,536,000 s/ 1 year) =

347.1598415 gallons/year

2008 to Present Water Cost to V of M (Less Service Fees)

Month 2008 Gallons 2009 Gallons 2010 Gallons 2011 Gallons

Jan $36,385.72 $25,006.76 $24,284.48 $24,475.71

Feb $29,739.50 $19,304.08 $23,164.74 $18,946.80

Mar $26,637.66 $28,866.60 $28,660.76 $19,820.51

Apr $33,450.34 $31,412.59 $27,169.52 $21,459.13

May $38,817.66 $30,185.73 $26,299.06 $33,939.98

Jun $41,598.76 $39,474.16 $38,947.99 $38,848.11

Jul $39,503.80 $34,177.08 $40,483.07 $44,375.39

Aug $42,853.30 $32,400.83 $39,267.91 $44,318.96

Sep $45,045.70 $32,891.68 $37,112.87

Oct $31,010.28 $23,326.73 $33,078.85

Nov $26,726.98 $22,596.74 $33,043.12

Dec $26,771.64 $24,470.84 $27,008.34

Total Usage $418,541.34 $344,113.83 $378,520.70 $246,184.60

Water Charge Rate $0.00406 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 $21,253.51 $25,504.03 $20,636.65

Mar $29,327.67 $31,781.70 $31,065.16 $21,745.21

Apr $36,828.33 $32,498.60 $27,389.48 $22,171.65

May $40,574.19 $27,923.24 $25,103.97 $29,881.06

Jun $43,546.74 $24,432.13 $29,402.77 $30,627.99

Jul $40,596.54 $26,440.94 $27,849.44 $32,720.40

Aug $42,697.44 $23,669.99 $26,736.86 $34,212.49

Sep $45,951.60 $25,858.50 $25,504.03

Oct $33,636.75 $23,451.86 $31,065.16

Nov $29,426.01 $24,063.35 $27,389.48

Dec $29,475.18 $26,942.03 $25,103.97

Total Output $444,863.34 $315,847.92 $328,851.20 $218,933.45

Village Sewer Charge Rate: $0.00447 per gallon

Month-2010 Incoming Gallons

Sewered Blow

Down Gallons Difference Savings

January 0 0 0 $0.00

February 0 0 0 $0.00

March 124,000 14,400 109,600 $489.91

April 657,000 92,400 564,600 $2,523.76

May 1,114,000 260,500 853,500 $3,815.15

June 3,175,000 748,700 2,426,300 $10,845.56

July 3,776,000 860,100 2,915,900 $13,034.07

August 3,687,000 926,800 2,760,200 $12,338.09

September 1,848,000 401,000 1,447,000 $6,468.09

October 820,000 120,100 699,900 $3,128.55

November 341,000 22,400 318,600 $1,306.26

December 0 0 0 $0.00

Total: 15,418,000 3,446,400 12,095,600 $53,949.45

Cooling Tower Evaporation Rate versus Sewered Blow Down Metering Savings Analysis

Sustainability in Waste Water Reduction

Sustainability = Green

Improving Efficiency and Reducing Costs

A Hagenism on

the Basics of WWT

“It always flows downhill and

if it stinks don’t eat it.”

Alternatives in Energy Sustainability

Carpe diemLatin

Enjoy the day; Seize today's

opportunities;Literally - Seize the day.