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Title of presentationGSK Energy Efficiency practices in Utilities Operations and Capital Projects Implementation
SynopsisGSK started its energy efficiency journey in 2002, delivering a 44% energy reduction while production volume increased by 45%. Since then, GSK has implemented more than 350 energy projects. Our methodology consists of 2 important aspects:- the use of technology and management practices. The key technology is the Energy Management System that provides on-line data to allow efficient utilities operation and identification of energy saving opportunities. The GSK management practice in Singapore and its head Office has provided the catalyst and empowerment for the GSK staff to strive to achieve its ambition to be carbon neutral by 2050
3
44%
Achievement
Key Projects
4
The DriversEnable & sustain energy savings initiatives
The ProjectAutomated energy targeting and monitoring system
(Rockwell) since July 2005
Server & data concentrators link with IT office network.
Web based for site wide access by all users
132 power meters, 13 flow meters, 26 temperature
transmitters.
Added new flowmeters for compressed air usage as part of
air compressor asset replacement project scope. Added
new power meters for new plant expansion. Approx. 70%
of site equipment (based on kw) are monitored via power
meters.
Benefit Detect significant unexpected deviations from normal
consumption patternDiagnostic, target setting, identify opportunities,
benchmark, calculate efficiency, quantify savings. Baseline usage
Report usage – auto reports
TECHNOLOGY –Energy Mapping & Metering
Corporate
-Best practices
-Site target
-Partnership with vendors
-Energy review-capex
=> Energy diagnostic events-Kaizen
BMAC
-Best practices
-Other industries
EMS
-Detail usage data
-Prioritize projects
-Verify savings
Energy
Management TeamTracker
- Tier accountability
- Project status
- Monthly CO2 saving
reporting vs target
Government
Support
MANAGEMENT PRACTICES
Process
-Energy review-PMP
-Equipment standardization
-Asset replacement – embed
energy efficiency
Recognition
-ERA, JDI
Maintenance-condition monitoring-vibration, thermal scan-preventive maintenance, tube cleaning
Energy Management & staff engagement
7
• Energy Management team sponsored by site Directors. All departments are represented. Regular meeting to review energy usage and track project status.
• Staff engagement from regular Friday Exchange messages and annual campaigns
Sharing – Singapore pharmaceutical industry
800 Month 0000Presentation title in footer
• GSK has led the Biopharmaceutical Advisory Committee (Sustainability workstream), since its formation in 2011 by Singapore’s Economic Development Board
• Energy Managers from 12 Biomedical companies meet regularly to share best practices and project ideas.
• Collective target to reduce 6% energy usage every year.Excellent results achieved , 2011: 7.4% reduction. 2012: 9% reduction. 2013: 6.2% savings. 2014: 6.2% savings. 2015: 4% savings. 2016: 5.4% reduction. 2017: 5% savings
• The voice for the Biomedical industry to feedback to government agencies.
PROJECT TITLE: Cooling Tower Water Treatment Process Redesign
BEFORE
Poor water treatment control
- reduce coolinng tower and chiller
efficicncy ( fouling & scaling)
- higher chemical usage ( cost)
- higher water usage ( cost)
- more labour for cooling tower
& chiller tube cleaning ( cost)
- manual weekly monitoring
condenser
Chiller
cooling tower
conductivity meter
& blowdown valvedos ing pump with timer
& chemical drum
water top-up
- reduce cooling tower and chiller
efficiency
AFTER
Improvement
-precise chemical dosing - use traser
molecules & feedback control
- interlock with dosing pump
- on line monitoring
detect abnormalitiy for quick reaction
Benefits
Annual energy saving 409 Mwh, $53k. Improve chiller efficiency by 5%. ROI = 0.3 years.
Reduce water usage
Reduce manpower for cooling tower cleaning and chiller tube cleaning.
Reduce water treatment chemical usage
- smart logic - blowdown valve
cooling tower
3D Trasar
Chiller
condenser
blowdown valve control synchronisedwith dosing pump
dosing pump controlled by concentration of chemical in the system
alarmmonitoring
cooling tower water is sampled to measure chemical concentration, water quality & conductivity
water top -up measured
Challenges Initial Cost. Included other benefits –reduce safety risk, prolong equipment lifespan and reduce maintenance cost.
Learning pointsCyber security risk. Did a Risk Assessment
Project conceivedThe project idea was triggered by an audit done by our HQ. Support from HQ
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