Dartford Electrical Energy Survey Report Rev F

Customer Name: GlaxoSmithKline Services & Projects
Your Ref: Our Ref: D1.00405

Project Name: Electrical Energy Survey Page Number 1

Electrical Energy
Survey

GSK

Dartford facility

Name Position Signature Date
Project led by: David Snow Senior Energy Consultant

25/7/08
Assisted by: Nick Ignadossian Power Consultant
Andy Turtle Motors & Drives specialist
Steve Gordon Energy Services Technical
Manager

Authorised for Issue: Kevin Jones Consultancy Solutions Manager


Table of Contents

1 Executive Summary........................................................................................... 3
2 Summary of Options.......................................................................................... 4
2.1 Energy Saving Calculations ....................................................................... 6
3 Background ....................................................................................................... 9
4 Options............................................................................................................ 11
4.1 Tariffs, Billing & Consumption.................................................................. 11
4.2 Metering & Monitoring.............................................................................. 17
4.3 Motors...................................................................................................... 24
4.4 Lighting.................................................................................................... 30
4.5 Power Quality and Availability.................................................................. 40
4.6 Building Controls & Building Management Systems................................. 44
4.7 Voltage Reduction ................................................................................... 53
5 Appendices...................................................................................................... 54


1 Executive Summary

This report details the findings of an electrical efficiency audit undertaken by
Schneider Electric at GSK, Dartford, UK. The survey was undertaken between April
and June 2008.

The annual electricity consumption for the site for the period April 2007 to March
2008 was 41,670,734 kWh with an associate cost of 2,080,314.

Of the savings identified, 30,000 p.a. may be achieved with no capital expenditure.
A saving of approximately 140,000 p.a. may be achieved from implementing
measures with estimated CAPEX of 430,000 providing a Simple Payback (SPB) of
3 years.

Implementation of all measures would save approximately 7% of the current utility
spend. This equates to approximately 3,040 MWh of electricity per year. Indirect
carbon dioxide savings related to this are estimated at 1,337 tonnes.

We would like to acknowledge the help and assistance given to us by Phil Broszek,
Chris Couves, Phil Garland (Johnson Controls) and Allen Higgs (BAS) for providing
us with essential information and assistance.


2 Summary of Options

The following is a summary of the energy saving measures. Energy price per units are averaged at 4.58p per kWh for electricity.
CO2
(tonnes) kWh
Basis for Revenue
calculation
Lighting Building 224 4.4.2
Install lighting controllers into rooms as detailed in Appendix 1.
Priority areas include store racking area, engineers store,
foxglove room, goods out, tabloid room and museum. 785 8 17,128 Reduced lighting hours 2,113 8.11 Supply & install PIR's 2.69 2 Medium
Priority areas include rooms 316, 301,324, 315, corridors and
stairwells. 1,158 11 25,272 Reduced lighting hours 4,370 5.78 Supply & install PIR's 3.77 5 Low
Prioirity areas include Mezzanine plant room, and left and right
voids; first floor voids, process area and material store; ground
floor process area and entrance lobby. 2,047 20 44,659 Reduced lighting hours 3,494 12.78 Supply & install PIR's 1.71 5 Medium
Priority areas include Ground floor process areas, clean corridor,
goods in and service void; and 1st, 2nd and 3rd floor process
area and service voids. 3,032 29 66,165 Reduced lighting hours 6,911 9.57 Supply & install PIR's 2.28 5 Medium
Priority areas include goods in and warehouse. 1,207 12 26,327 Reduced lighting hours 1,564 16.83 Supply & install PIR's 1.30 5 Medium
Priority areas include office corridor, ground floor entrance, clean
corridor, process area, and service voids; 1st, 2nd and 3rd floor
process areas and service voids 3,980 38 86,848 Reduced lighting hours 7,142 12.16 Supply & install PIR's 1.79 5 Medium
Priority areas include finished product store, process areas and
service voids. 1,494 14 32,610 Reduced lighting hours 4,731 6.89 Supply & install PIR / PEC 3.17 1 High
Priority areas include ground floor goods in / out and entrance;
first floor process corridor and outsode corridor; and second floor
main area. 2,324 22 50,717 Reduced lighting hours 5,525 9.18 Supply & install PIR's 2.38 1 High
Priority areas include ground floor internal corridor, G33 lab, G37
fume cupboard, G25 plant room and G16 Lab; 1st floor main
corridor and plant room; and 2nd and 3rd floor plant rooms. 2,959 28 64,567 Reduced lighting hours 9,040 7.14 Supply & install PIR's 3.06 1 High
Priority areas are the corridors 268 3 5,839 Reduced lighting hours 792 7.37 Supply & install PIR's 2.96 3 Medium
The main area will yield the greatest savings. 747 7 16,296 Reduced lighting hours 744 21.90 Supply & install PIR's 1.00 3 High
All areas have similar characteristics. 604 6 13,181 Reduced lighting hours 1,806 7.30 Supply & install PIR's 2.99 3 Medium
Lighting Building 444 4.4
Install lighting controllers onto the contractors compound in the
following areas: Cabin 11, unit 10, Unit W62, Tarvail workshop,
and Thomson electrical office 160 2 3,481 Reduced lighting hours 160 21.76 Supply & install PIR's 1.00 4 High
Priority areas include main open plan office and training area. 507 5 11,052 Reduced lighting hours 1,682 6.57 Supply & install PIR's 3.32 3 Medium
Lighting Building 468 4.4.4 Install lighting controllers into the restaurant 148 1 3,223 Reduced lighting hours 854 3.77 Supply & install PIR's 5.78 1 Medium
Sub System Key Area Scope of Investment& cost
Ease of
Implementation (1
Easy, 5 Hard) Priority
Report
reference
pay back
[a]
Estimated Annual Savings
Estimated
Cost () Recommendation for Improvement
kWh saved
per spent


CO2
(tonnes) kWh
Basis for Revenue
calculation
Tariffs & Billing Site 4.1.5 Reduce base load consumption as detailed in the energy audit 8,459 81 184,577
Reducing off peak base
load by 10% (see energy
audit) Time
Install metering, software and
manage M&T system as detailed
in the energy audit report 3 High
Monitoring &
Targeting Site 4.2 Install M&T system as detailed in the energy audit 60,000 576 1,309,216
From best practice case
studies (see energy audit
report) 120,000 10.91
Install metering, software and
manage M&T system as detailed
in the energy audit report 2.00 3 High
BMS Offices 4.6 Recommission BMS system as detailed 6,233 60 135,997
Tighter control of HVAC
plant 30,000 4.53
Install & commision outstations
and provide communications to
head end 4.81 3 Medium
Motors & Drives Building 449 4.3
Replace existing motors (appendix 8) with high efficiency motors
as follows: Cooling water pumps 1 &2, secondary cooling water
pumps 1&2, cooling tower fans 1-5 (duty / standby), condensor
pump and primary cooled water pumps. 4,755 46 103,756 Increase motor efficiency 30,449 3.41 Supply and install new motors 6.40 4 Low
Replace existing motors with high efficiency motors as follows:
LTHW return pumps 1 & 2, primary chilled water return,
secondary chilled water return 1 & 2, air handling fans *3 953 9 20,793 Increase motor efficiency 6,092 3.41 Supply and install new motors 6.39 4 Low
Motors & Drives Building 227 4.3 Replace feed water pump motor 3 with high efficiency motor. 188 2 4,100 Increase motor efficiency 1,212 3.38 Supply and install new motors 6.45 4 Low
Motors & Drives Building 436 4.3 Replace process pump motor with high efficiency motor. 250 2 5,446 Increase motor efficiency 1,923 2.83 Supply and install new motors 7.70 4 Low
Replace HTF pump motor 1 & 2 with high efficiency motors as
detailed in the report 587 6 12,808 Increase motor efficiency 4,944 2.59 Supply and install new motors 8.42 4 Low
Replace hydraulic pump motor with high efficiency motor as
detailed in the report 111 1 2,414 Increase motor efficiency 771 3.13 Supply and install new motors 6.97 4 Low
Replace existing motors with high efficiency motors as follows:
Interceptor tank, Acetone supply pump, low temp HTF circulating
pumps 1 & 2 604 6 13,172 Increase motor efficiency 4,821 2.73 Supply and install new motors 7.99 4 Low
Motors & Drives Building 227 4.3 Install invertors onto feed water pump 3 680 7 14,836 Reduce motor loading 4,141 3.58 Supply & Install invertor drives 6.09 4 Low
Motors & Drives Building 404 4.3 Install invertors onto dust exhaust fan, and LTHW pumps 1&2 3,654 35 79,729 Reduce motor loading 23,897 3.34 Supply & Install invertor drives 6.54 4 Low
Motors & Drives Building 405 4.3 Install invertors onto process area extraction fans 1,707 16 37,256 Reduce motor loading 11,686 3.19 Supply & Install invertor drives 6.84 4 Low
Motors & Drives Building 407 4.3 Install invertors onto blender motor.. 424 4 9,250 Reduce motor loading 3,625 2.55 Supply & Install invertor drives 8.55 4 Low
Install invertors onto 4no air handling fans, primary chilled water
return pumps 1&2, LTHW preheat return pumps 1&2, secondary
chilled water return pumps 1&2. 4,932 47 107,621 Reduce motor loading 27,518 3.91 Supply & Install invertor drives 5.58 4 Low
Motors & Drives Building 436 4.3 Install invertors onto process pump motors 1&2 1,715 16 37,424 Reduce motor loading 11,154 3.36 Supply & Install invertor drives 6.50 4 Low
Install invertors onto 3no condensor pumps, 2no primary cooled
water pumps, cooling tower 5 fan motors, and air compressor 2. 21,569 207 470,643 Reduce motor loading 85,622 5.50 Supply & Install invertor drives 3.97 4 Medium
pay back
[a]
Ease of
Implementation (1
Easy, 5 Hard) Priority
Estimated Annual Savings
Estimated
Cost ()
kWh saved
per spent Scope of Investment& cost Key Area Sub System
Report
reference Recommendation for Improvement



2.1 Energy Saving Calculations

Assumptions made in the energy saving calculations are as follows:
2.1.1 Tariffs & billing

A reduction of the base load in off peak times is calculated using the following
assumptions:
Sum of all consumption for Year ending March 2008 for weekend days only =
9,228,857kWh. Assuming that this represents off peak (although some
weekends are peak, holiday periods are not included). Assume a 10%
reduction in this off peak period is feasible through actions detailed in section
4.1.5.
2.1.2 Monitoring & Targeting

Energy savings related to implementing a good monitoring & targeting system can
yield savings of at least 5% in buildings and 1% in production areas. This information
is obtained from the UK Carbon Trust Good Practice guide 112, Monitoring &
Targeting in large companies. Several case studies within this guide have indicated
that the typical savings were between 1.8% and 14% across a number of different
industries.
2.1.3 Motors & Drives

Variable Speed Drives
The following simple calculation is used for variable speed drives:

A Assume current power loading (75%)
B Assume current utilisation factor (hours used)
C Assume % flow reduction after VSD fitted
D Obtain Motor rating (kW)

Energy saving = (A*B*D) (B*D*(C^3))
Ie Power Saving = flow saving^3

High Efficiency Motor replacement

Where data has been available and recorded, full load efficiencies have been
calculated and are compared to the EFF rating scheme.

Full load efficiencies have been calculated, where data was available, as follows:

Efficiency % = Rated power x 100
Input power

and Input Power = 3 x voltage x full load current x power factor

Where the data is incomplete, the EFF2/EFF3 boundary efficiency figure has been
used, in line with CEMEP guidance.



Where the measured full load current is available, the spot percentage loading of the
motor is calculated. Otherwise, 75% has been assumed.

Full load efficiencies have been used. Modern high efficiency motors tend to have a
flatter load/efficiency curve than conventional motors, so the efficiency gain may well
be better than assumed at less than full load, as most motors will be.

The potential annual saving has been calculated as follows:

Saving = Input power x loading % x annual hours x efficiency delta x 4.58p

Motor cost is based upon Brook Crompton price list, less 45%, plus 50% for
installation. Costs for a flange mounted model have been assumed as the more
expensive. Prices are based on safe area classification only.
2.1.4 Lighting

All lighting details are included in Appendix 1. Assumptions on run hours have been
derived through occupancy statistics and evidence from the site surveys. In areas of
high occupancy, it is assumed that the lighting hours can be reduced by 10%,
otherwise light hours can be reduced by 30% through automatic controls. Where
lights are switched off, it is assumed that the area follows good practice and only
10% savings on hours used is possible.

Only areas where the installed lighting exceeds kW are considered for automatic
controls.
2.1.5 BMS

Best practice case studies indicate that around 18% savings can be achieved
through implementing a good BMS system where none previously exists. The
following yardsticks (based on UK government statistics) can be used for estimating
heating and cooling usage:

Heating
& Hot
Water Cooling
Fans,
Pumps,
Controls
Good
practice
97 14 30
Air-conditioned,
standard offices
Typical
kWh/m2
p.a. 178 31 60
Good
practice
107 21 36
Air-conditioned,
prestige offices
Typical
kWh/m2
p.a. 201 41 67
Good
practice
220 0 20
General
Manufacturing
Industrial
Building
Typical
kWh/m2
p.a. 320 0 30

For the calculations, it is assumed that the areas with BMS installed are not running
to the optimum efficiency, and are only gaining half of the savings, then energy
savings will be around 9% of the buildings concerned. It is also assumed that the
buildings fall into the typical category of the above matrix.



2.1.6 Conclusion

The cost and hence ROI of all measures take no account of depreciated asset
values. If some of the asset value can be written down, then the return on
investment figures would improve accordingly.

All the assumptions above used in the calculations need to be validated through
further investigation and adjustments made accordingly.



3 Background

GSK Dartford is situated 1 mile due north of Dartford in Kent and covers an area of
approximately 35 acres.

The Dartford site has been home to pharmaceutical manufacturing since 1889 when
the Wellcome Foundation officially opened on 3 July.

Until a few years ago, the site was home to a large secondary manufacturing facility
and a small R&D facility (chemical development), as well as the existing primary
manufacturing facilities.

In January 2000 Dartford received the go-ahead for a 23 million investment for a
new valaciclovir facility on the North Site, and in January 2003, a proposal was
announced to cease primary manufacturing on the East - and older -part of the
Dartford site by the end of 2006. Primary manufacturing at Dartford was to be
focused on the North site.

Dartford is responsible for manufacturing around 12 active ingredients for customers
around the world and is also a 'new product introduction' site, with a sustained record
of helping to bring new products to the market.

The site has received significant investment during recent years to build new state-of-
the-art manufacturing facilities, improve and expand existing ones, as well as a new
staff restaurant, a Conference Centre and a new Site Reception and Security
building.

The site now comprises of office accommodation, laboratories, packaging areas,
warehousing and clean room processes. There is also an energy centre (buildings
241 and 227) which houses a gas turbine and steam boilers although there are plans



to decommission these buildings and build new facilities in the North West corner of
the site.

There are approximately 600 GSK personnel and a further 400 contracted personnel
working on the site with a 2 shift pattern in the process areas. The processes are run
24 hours a day, 365 days per year.

It is understood that the majority of the buildings in the South East section of the site
will be vacated in due course, and operations will move to the main part of the site.
This will include the following buildings:

Building 241 Combined heat and power plant
Building 227 Boilerhouse
Building 225 General Offices

Therefore, only opportunities with short paybacks were considered in these areas.



4 Options
4.1 Tariffs, Billing & Consumption
4.1.1 Supplier Tariff

The site electricity consumption has been calculated from the energy bills provided
by RWE NPower. The electricity tariff is currently based on a seasonal time of day
tariff with an availability charge on an agreed supply capacity of 15,000 kVA which
equates to 4,755 per month. It is understood that this tariff is an annual contract,
renewable each October. Details of this tariff are as follows:

There are no charges relating to maximum demand (MD), although the MD should be
around 80% of the available capacity so that there is capacity for unexpected peaks,
but there are no unnecessary availability charges. However, this is not the case as
illustrated in the following chart:
MD v SC
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
Jan-
06
Feb-
06
Mar-
06
Apr-
06
May-
06
Jun-
06
Jul-
06
Aug-
06
Sep-
06
Oct-
06
Nov-
06
Dec-
06
Jan-
07
Feb-
07
Mar-
07
Apr-
07
May-
07
Jun-
07
Jul-
07
Aug-
07
Sep-
07
Oct-
07
Nov-
07
Dec-
07
Jan-
08
Feb-
08
Month
MD (kW)
SC (kVA)



It is quite apparent that the supply capacity is far too high, and that around 8,000 kVA
would be adequate. This will need to be negotiated with RWE NPower, but if this can
be reduced, charges for 7,000 kVA capacity can be saved. This will equate to
26,628 per annum.

The site profile for week commencing 4/6/07, which represents the daily profile with
the highest demand (Monday 7
th
June) is as follows:

Week - kW profile
0
1000
2000
3000
4000
5000
6000
7000
0
1
:
0
0
0
3
:
0
0
0
5
:
0
0
0
7
:
0
0
0
9
:
0
0
1
1
:
0
0
1
3
:
0
0
1
5
:
0
0
1
7
:
0
0
1
9
:
0
0
2
1
:
0
0
2
3
:
0
0
Mon
Tue
Wed
Thu
Fri
Sat
Sun

This slightly higher consumption will most likely be attributed to the need for comfort
cooling as the weather was quite hot at this time. The peak at the beginning of
Thursday is a data anomaly and should be ignored.

Total consumption for the year April 2007 to March 2008 was 41,670,734 kWh with
an associated cost of 2,080,314 inclusive of CCL (Climate change levy). The cost
takes into account a flexible purchasing reconciliation which resulted in a credit to the
site of just over 258k for this period. There is a CCL agreement whereby 80% of the
consumption is exempt from the charge due to the intensive processes which GSK
claims. However, an action plan with targets needs to be adhered to for the
exemption to be given. If these targets are not met, there is a risk of losing the
exemption which would cost the site approximately 147k per annum.

Triad notices

At the end of the winter season (November 1st to February 28th), National Grid
identifies the three half-hour periods of highest consumption of electricity, subject to a
separation of at least 10 calendar days. These three periods are called Triads. Thus,
the half-hour in which national demand was highest is the first Triad; the second
highest half-hour, excluding a period of 21 days centred on the first Triad, is the
second Triad; and the third highest half-hour, excluding two periods of 21 days
centred on the first and second Triads, is the third Triad. Historically, Triads always
occur on Mondays to Thursdays between 16:30 and 18:00 hours, and not close to
Christmas (which is a period of relatively low consumption).

The site receives Triad warnings each year, and the site has to load shed to avoid
paying big penalties on the three highest periods, which are unknown until the end of
the season. It is not effective to load shed for all of the triad warnings and it is
common for end users to be penalised for the Triads. The penalties come in the form
of TUOS charges (Transmission Use of System) and a charge of 22.16 per kW of
demand during the Triad period is chargeable for the year. In 2007, the kW charge
was 1852.8kW which resulted in a monthly charge of 3,422.18.



The load during the three Triad warnings were as follows:

20/12/06 17:30 5,340 kW
23/1/07 17:30 100 kW
8/2/07 18:00 80 kW

The average of these three loads, multiplied by the network operators loss
adjustment factor, results in the penalty incurred for the following year. The first Triad
was missed and the site continued to run as normal. However, the second two
warnings were adhered to and standby generation was turned on which reduced the
imported electricity consumption considerably. The charge in 2006 was 3390kW, but
2008 has resulted in a high charge as two of these warnings were not observed:

26/11/07: 5040kW
17/12/07: 260 kW
3/1/08: 5220kW

In March each year, the National Grid publishes the three highest maximum demand
(MD) readings that have occurred between November in the previous year and
February in the current year. The invoices therefore include a triad reconciliation
figure following this announcement. This figure will reconcile the difference between
the annual transmission charges and National Grids final triad charge. In 2007, this
figure equated to a credit of 24,824.13. However, in 2008, the reconciliation figure
has resulted in a debit of 40,622.84 as only one warning was observed.
4.1.2 Forward electricity prices

The following table provides historical and forward contract prices for electricity in the
UK market:
Electricity Month ahead prices
0
20
40
60
80
100
120
O
c
t
-
0
5
J
a
n
-
0
6
A
p
r
-
0
6
J
u
l
-
0
6
O
c
t
-
0
6
J
a
n
-
0
7
A
p
r
-
0
7
J
u
l
-
0
7
O
c
t
-
0
7
J
a
n
-
0
8
A
p
r
-
0
8
J
u
l
-
0
8
O
c
t
-
0
8
/
M
W
h
Average prices
Max prices
Min prices

The prices here are based on month ahead quotations, with the data collected on a
daily basis for the proceeding four months. The maximum and minimum prices show
how the months prices vary during the proceeding four months. For example, prices
for July 08 were analysed from March to June and varied from 56 /MWh to
87/MWh. This indicates the volatility of the market whereas the previous summer
was a lot less volatile.

As expected, the following chart illustrates that when the market is dropping, it is best
to buy late, and when the market is rising, it is best to buy as early as possible:



Time to buy
0
20
40
60
80
100
120
0
5
/
0
8
/
2
0
0
5
0
5
/
1
0
/
2
0
0
5
0
5
/
1
2
/
2
0
0
5
0
5
/
0
2
/
2
0
0
6
0
5
/
0
4
/
2
0
0
6
0
5
/
0
6
/
2
0
0
6
0
5
/
0
8
/
2
0
0
6
0
5
/
1
0
/
2
0
0
6
0
5
/
1
2
/
2
0
0
6
0
5
/
0
2
/
2
0
0
7
0
5
/
0
4
/
2
0
0
7
0
5
/
0
6
/
2
0
0
7
0
5
/
0
8
/
2
0
0
7
0
5
/
1
0
/
2
0
0
7
0
5
/
1
2
/
2
0
0
7
0
5
/
0
2
/
2
0
0
8
0
5
/
0
4
/
2
0
0
8
0
5
/
0
6
/
2
0
0
8
Date of quote
/
M
W
h
Oct-05
Nov-05
Dec-05
Jan-06
Feb-06
Mar-06
Apr-06
May-06
Jun-06
Jul-06
Aug-06
Sep-06
Oct-06
Nov-06
Dec-06
Jan-07
Feb-07
Mar-07
Apr-07
May-07
Jun-07
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Jul-08
Aug-08
Sep-08
Oct-08
Nov-08

Early indications for the winter are that the prices will be a lot higher, with the trend
for the last few months seeing the electricity price increasing at an alarming rate.

Using the current STOD tariff, average unit prices are as follows:

Rate Unit price ( per
MWh)
% of total consumption
1 34.96 28.5%
2 43.57 22.1%
3 50.03 47.2%
4 123.39 2.1%

The average price across the year ending March 2008 equates to 45.80 per MWh.
Average best month ahead prices for the same period are 30.20 per MWh, up to
42.43 for the worse prices. However, this contract rate is from October 07 to
October 08. Best and worse average electric prices for this period equates to 50.50
per MWh and 71.50 per MWH respectively. Therefore, the current unit prices are
good for this climate, but a price hike in October must be expected.
4.1.3 Billing procedures

The bills are currently received by the accounts payable department in Mitcheldean,
Gloucestershire where they authorise them for payment and subsequently pay them.
The engineering team at Dartford later receive the bills which they enter onto a
spreadsheet and the hardcopies are then filed. The spreadsheet is primarily used for
internal meetings.



As there is no procedure for reconciling the bills against half hourly data, it is
recommended that a more robust billing monitoring system is introduced as
discussed in section 4.2.
4.1.4 Consumption profile

The consumption profile for the site is extremely flat, with no peaks and troughs
through the day, days of weeks or even weeks in the year. This is illustrated by the
following profile, which is for week commencing 24/12/07, (Christmas):

Week - kW profile
0
1000
2000
3000
4000
5000
6000
0
0
:
0
0
0
2
:
0
0
0
4
:
0
0
0
6
:
0
0
0
8
:
0
0
1
0
:
0
0
1
2
:
0
0
1
4
:
0
0
1
6
:
0
0
1
8
:
0
0
2
0
:
0
0
2
2
:
0
0
Mon
Tue
Wed
Thu
Fri
Sat
Sun

The daily consumption profile for the year ending 31
st
March 2008 is as follows:

0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
0
1
/
0
4
/
2
0
0
7
1
5
/
0
4
/
2
0
0
7
2
9
/
0
4
/
2
0
0
7
1
3
/
0
5
/
2
0
0
7
2
7
/
0
5
/
2
0
0
7
1
0
/
0
6
/
2
0
0
7
2
4
/
0
6
/
2
0
0
7
0
8
/
0
7
/
2
0
0
7
2
2
/
0
7
/
2
0
0
7
0
5
/
0
8
/
2
0
0
7
1
9
/
0
8
/
2
0
0
7
0
2
/
0
9
/
2
0
0
7
1
6
/
0
9
/
2
0
0
7
3
0
/
0
9
/
2
0
0
7
1
4
/
1
0
/
2
0
0
7
2
8
/
1
0
/
2
0
0
7
1
1
/
1
1
/
2
0
0
7
2
5
/
1
1
/
2
0
0
7
0
9
/
1
2
/
2
0
0
7
2
3
/
1
2
/
2
0
0
7
0
6
/
0
1
/
2
0
0
8
2
0
/
0
1
/
2
0
0
8
0
3
/
0
2
/
2
0
0
8
1
7
/
0
2
/
2
0
0
8
0
2
/
0
3
/
2
0
0
8
1
6
/
0
3
/
2
0
0
8
3
0
/
0
3
/
2
0
0
8
T
o
t
a
l

D
a
i
l
y

k
W
h

Other than a couple of instances, it is illustrated that the profile is fairly flat on a daily
basis which indicates that the processes run constantly. The drops in consumption
are due to the following:

Week commencing 17
th
December was a Triad period which was observed. It
is understood that the Gas turbine was running for a few days following this
period.
Monday 23
rd
April had a small dip due to a production shutdown



There is a significant dip in September, with the following profile on week
commencing 17
th
September 2007 being more than 20% lower than normal,
with a weekly consumption of 638,700kWh. The Wednesday had a significant
drop with a maximum demand of less than 3,000kW.
It is understood that this weeks profile is lower than normal because there was a
shutdown of the chilled water from building 449. As all the production areas rely upon
the chilled water, it would also mean that the production was shut down during this
period. This would explain the dip in consumption, but it is quite alarming that with no
production on site, the base load is still around 60% of peak consumption.
4.1.5 Tariffs, Billing and Consumption Recommendations

It is recommended that:
a) The supply capacity is reviewed and reduced to 7,000kVA
b) It is recommended that activity is reviewed during periods of shutdown as
the base load appears excessive. The likely causes are as follows:
Primary Processes - Heat elements, Cooling elements, agitators and
compressed air provision when the process is not running.
Secondary Processes Conveyors, packing machines.
Heating, Ventilation and Air Conditioning (HVAC) Extract fans
especially may be left on in areas where it is not required.
Lighting Lighting may be left on when areas are unoccupied.

A reduction of 10% in periods of inactivity is likely to result in an energy saving
of 185 MWh p.a. (Total weekend usage equates to 9,228MWh, possible shut
downs estimated at every fifth weekend).

Savings related to the above equate to 38,891 with no additional capital costs.

It is also recommended that further investigation is undertaken to ascertain
whether the tariff structure fits correctly. There may be opportunities to buy
month ahead, or negotiate an increase in reactive power charge and a smaller
unit rate. An increase in reactive power charge will benefit the site should it
implement the recommendations discussed in section 4.7.
Week - kW profile
0
1000
2000
3000
4000
5000
0
1
:
0
0
0
3
:
0
0
0
5
:
0
0
0
7
:
0
0
0
9
:
0
0
1
1
:
0
0
1
3
:
0
0
1
5
:
0
0
1
7
:
0
0
1
9
:
0
0
2
1
:
0
0
2
3
:
0
0
Mon
Tue
Wed
Thu
Fri
Sat
Sun



4.2 Metering & Monitoring

To control energy consumption and costs, regular and reliable records of energy
usage should be maintained. These records will help to identify changes in energy
costs and consumption. The simplest form of Monitoring and Targeting is to
record monthly energy usage which can be monitored and graphed on a computer
spreadsheet or a specialised computer based system. This information can be
obtained from invoices or by reading the meters.

Continuous assessment of consumption is required so that both the plant and
controls continue to operate as intended, and to also ensure that the occupants
behaviour continues to operate a good housekeeping policy. Energy savings can
be short lived, if the initial impetus is allowed to decrease.

A monitoring and targeting system should:-
Record energy consumption and any other factors that affect energy use
(weather, occupancy, etc.)
Compare the energy use to previous years, or to yardsticks representing typical
or target energy performance
Alert sudden changes in energy use patterns
Provide regular summary reports.
Provide the relevant cost centers with their individual energy costs.

The system at GSK Dartford involves the monitoring of utility bills only, with
comparisons to production. This includes year on year performances with kg v kWh,
cumulative sum charts and comparisons to degree days. This is good practice, but
only with increasing the number of data streams will the full benefits of monitoring
and targeting be realised.
4.2.1 Metering

The initial method of increasing data streams will be through the introduction of
automatic metering. Data will be collected from a number of meters across the site
every half hour, and accurate profiles of consumption will be produced for all areas.
This data can then be analysed against further production figures and other
variables. It is understood that many of the new meters have been purchased but not
yet installed due to no available shutdown periods.

In section 4.5 of this report (power quality and availability), the electrical single line
diagram is provided. This is useful as reference for the metering strategy. The
following table details the existing metering system and includes the following meter
types:
E Electric
G Gas
W Water
S Steam
A Air
V Virtual (Consumption is calculated from aggregating actual meters)


Ring Main
Feeder Building No / Area
Meter
type Meter Description
RMF1 241 CHP / Switchroom E Main Meter
RMF 10 442 132kV Sub E Main Meter
449 Water Resources E Transformer 1
449 Water Resources E Transformer 2
449 Water Resources E Condensor Water
449 Water Resources E Cooling Water
449 Water Resources E Primary cooled water
449 Water Resources E Secondary Cooled water
449 Water Resources A
436 Gas EMC Incinerator G
436 Elec EMC Incinerator E
436 Steam EMC Incinerator S output
436 11kV sub E Transformer 1
436 11kV sub E Transformer 2
400 Production E Switchfuse N
400 Production E Switchfuse M
400 Production S
401 Production E Transformer 1 B422
401 Production E Switchfuse V
401 Production E Switchfuse U
401 Production S
403 Warehouse E
404 Production S
427 Technical development E Transformer 1
427 Technical development S
RMF2 241 CHP / Switchroom E Main Meter
225 Offices E
225 Offices S
227 Boiler House E Supply 1
227 Boiler House E Supply 2
227 Boiler House E Water Treatment
227 Boiler House VS Boiler 1
227 Boiler House W Feedwater boiler 1
227 Boiler House G
227 Boiler House V Boiler 1 - 3 Thermal efficiency
RMF3 241 CHP / Switchroom E
241 CHP / Switchroom S From boiler 4
241 CHP / Switchroom W FW to boiler 4
241 CHP / Switchroom W FW Flash vessel
241 CHP / Switchroom E Transformer 1
241 CHP / Switchroom E Transformer 2
241 CHP / Switchroom G Comp 1
241 CHP / Switchroom G Comp 2
241 CHP / Switchroom V Thermal efficiency
241 CHP / Switchroom V Elec Efficiency
241 CHP / Switchroom V Combined efficiency
241 CHP / Switchroom VE Elec output
RMF 4 241 CHP / Switchroom E
RMF 5 241 CHP / Switchroom E


There are multiple meters monitored in the utilities plant areas (Boilerhouse, CHP,
Water services and Incinerators) and single meters at most of the buildings. The
following buildings have no electricity meters at all:

Building 405 - Production
Building 407 Grinding & Blending Unit
Building 417 Site Reception
Building 418 Changing facilities
Building 423 Gatehouse
Area 444 Contractors Compound
Building 445 Offices
Building 468 - Restaurant

Metering strategies recommended by the DETR, and now incorporated into Part L
Building Regulations, concludes that 90% of the incoming energy into a site must be
accounted for. The guide stipulates the requirements as follows:

Reasonable provision would be to enable at least 90% of the estimated annual energy
consumption of each fuel to be accounted for. Allocation of energy consumption to the various
end uses can be achieved using the following techniques:
- direct metering
- measuring the run-hours of a piece of equipment that operates at a constant known load
- estimating the energy consumption, e.g. from metered water consumption for hot water
services (HWS), the known water supply and delivery temperatures, and the known efficiency
of the water heater
- estimating consumption by difference, e.g. by measuring total gas consumption and
estimating the gas used for catering by deducting the measured gas consumption for heating
and hot water
- estimating non-constant small power loads using the procedure outlined in chapter 11 of
CIBSE Guide F: Energy efficiency in buildings(5).

Reasonable provision of meters would be to install meters in every building greater than 500
m2 gross floor area (including separate buildings on multibuilding sites). This would include:
- individual meters to directly measure total electricity and gas consumed within the building
- a heat meter capable of directly measuring the total heating and/or cooling energy supplied
to the building by a district heating or cooling scheme.

Reasonable provision of sub-metering would be to provide additional meters such that the
following consumptions can be directly measured or reliably estimated (see above):

- Electricity and gas provided to each separately tenanted area that is greater than 500 m2
- energy consumed by plant items with input powers greater or equal to that shown in Table
13 of Approved Document L2 (ADL2) (reproduced here below)
- any heating or cooling supplied to separately tenanted spaces; for larger tenancies, i.e.
those with floor areas greater than 2500 m2, direct metering of the heating and cooling may
be appropriate, but for smaller tenanted areas, the heating and cooling end uses can be
apportioned on an area basis.
- any process load that is to be discounted from the building's energy consumption when
comparing measured consumption against published benchmarks


Plant Item Rated power
input (kW)
Boiler installations comprising one or more boilers or CHP plant feeding a
common distribution circuit
50
Chiller installations comprising one or more chiller units feeding a
common distribution circuit
20
Electric Humidifiers 10
Motor control centres providing power to fans and pumps 10
Final electrical distribution boards 50

These regulations only apply to new buildings and existing buildings when they are
extended, and is not retrospective. However, it is good practice to follow these
guidelines, as further analysis will be beneficial (see section 4.2.2). GSK motor
management policy stipulates that new motors above 30kW need to have meters
installed, not the 10kW as Part L regulations suggest. In the instance of heavy
manufacturing, the regulations are not always practical, and careful consideration as
to the level of metering should be undertaken.

The following table can be used to ascertain the metering requirement:

STEPS 1-6
WORKSHEET
Start by identifying the largest three or four end uses that can be metered easily; then iterate until at least 905
of each incoming energy is metered.

STEP 1 Total annual fuel consumption (estimates) kWh / yr
Electricity Gas. Water

STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

Fuel
Type
Main end
uses
Estimated
Consumption
(kWh/yr)
End
use/area/
system/
circuit to
be
measured
Identify
any
existing
meters

Step 4.1
Measurement
method

Step 4.2
Meter
code

Step
4.3
Meter
type

Step
4.4
Calculation Estimated
energy
consumption
through
meter (kWh
/ yr)
Is
metered
within
90% of
incoming?
Yes / No

If no go
back to
step 3
ELECT. Incoming
1
st
iteration - Electricity
Lighting
Cooling
Compressed
Air

Processes

Is this 90% of incoming electricity?

2
nd
Iteration Electricity (additional metering)

Is this 90% of incoming electricity?

GAS. Incoming
1
st
iteration - Gas
Space
Heating

DHW
Catering

It is therefore recommended that one of these worksheets is filled initially for the
larger buildings to ensure that 90% of the buildings end use is monitored. This may
involve examining the distribution boards and identifying existing current transformers
(cts) for the installation of a meter.

It is also recommended that a worksheet is then filled out for the entire site, so that
90% of buildings are monitored.


4.2.2 Data Capture

Data is currently collected through the Honeywell Scada system, where meters are
connected to local control systems and are networked back to the main Scada
outstations. Every hour the consumption is aggregated and logged, so the resulting
consumption is in an hourly format. On a daily basis, a text file is uploaded to a stand
alone Montage software system. The software system is only accessed by Phil
Broszek where specific reports are generated and issued in PDF format via email.
The reports for Montage are only monthly as the variables that the consumption is
compared to is in monthly format (Degree days / production figures).

As previously mentioned, the more data collected, the better the output from the M&T
system. An ideal system would be collecting the consumption information in real
time, and compared to hourly or half hourly variables. The digital meters should
communicate through a network protocol and data should be collected as in
accordance with standard robust data capture techniques (See Appendix 3):
4.2.3 Monitoring & Targeting

By analysing meter data, it can easily be compared to a variable such as production
or external temperatures. The following chart illustrates how this analysis can be
undertaken using a regression analysis.
By plotting electricity v production, a linear trend line can be drawn. Equations in the
format of y=mx+c are derived, y being electricity consumption, x being the production
variable, m being the gradient of the line and c being the constant or base load that is
consumed when there is no production. This equation becomes the target and can
be further analysed as a CUSUM (Cumulative Sum) graph:

El e ctri ci ty vs Producti on
y = 558.08x + 124481
R
2
= 0.9146
y = 566.78x + 31475
R
2
= 0.9706
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Pr oduct ion ( pot s )
E
l
e
c

k
W
h


This analysis subtracts actual use from the predicted use (y=mx+c). The difference is
then added together each time the analysis is undertaken. On target would be
straight along the X axes, behind target would be below the axis and ahead of target
would be above the target. Exception reports can then be created when the actual
consumption deviates away from its target by an agreed tolerance.

By producing analysis in half hourly format by using real time analysis as detailed
earlier, target daily profiles can be created and exceptions can be created as follows:

It is also recommended that the following charts can be used:
Building League Tables (kWh / Production or Occupancy)
Year on Year consumption profiles
Year on year normalised consumption profiles (corrected for production/weather
etc)
Energy consumption v target

It is essential that a flexible system is used that supports tailored report templates,
ad-hoc report creation, 3
rd
party data import (ex: ERP systems, BMS systems, Power
Management systems, weather feeds), and user specific content display. Easy-to-
use Administration, Data Quality, and Data Management tools will help companies
maintain and grow their monitoring & targeting system. An example of this is included
in Appendix 6.


4.2.4 Recommendations

Energy saving opportunities are as follows:-
a) It is recommended that a full metering audit is undertaken and new meters
installed to ensure that 90% of the end use consumption is monitored on a half
hourly basis.
b) It is essential that a new software solution is implemented which can be flexible
and functional.
c) It is recommended that all contractors, who are cross-charged for their energy
usage, should have sub-meters installed. This information should be passed on
to the accounts department for cross-charging purposes, ensuring that standing
charges are taken into account within the calculations.

If possible, GSK should assess its existing staff structure and identify a part-time
operator to be solely responsible for collecting and monitoring energy consumption
as well as utility invoice validation. Key personnel should be identified, and a report
structure agreed whereby weekly/monthly reports on current performance are
distributed for use with the energy awareness program. Full procedures on the
operation of the M&T system should be kept, so that sufficient training can be given
should there be any staffing restructures.

Energy savings related to implementing a good monitoring & targeting system can
yield savings of at least 5% in buildings and 1% in production areas. It is estimated
that this will equate to 1,309,000 kWh or 60,000. The implementation cost for the
hardware of a system like this would be around 70,000 with software and training
costs around 50,000.


4.3 Motors

4.3.1 Introduction
GSKs objectives are to reduce energy consumption in the operation of their electrical
systems, whilst maintaining safe and reliable power supplies. Recognising the large
proportion of total electrical energy which is consumed by motors, GSK are putting a
high priority ensuring efficient use of motors. GSKs Motor Management Policy sets
out the expectation of the sites and this audit addresses the requirement to
proactively survey and review the motor asset base at 11kW rating and above.

This audit includes a non-intrusive survey of motors to collect, where possible, rating
plate data and information about the motors installed environments. The data
collected is analysed and the report provides information and commentary on the
motor efficiencies found and opportunities for motor replacement and/or variable
speed drive applications.

Other relevant recommendations are made, including any necessary further
investigations. These include a second stage intrusive audit for selected motors,
using monitoring equipment to examine actual load cycle and absorbed power.
4.3.2 Survey
The survey was based on the motors identified by the site, which totaled 207, of
which the output power ratings were positively identified for 139 motors. Some rating
plates were missing and it was not possible to view all motors for access reasons
they are inside air handling units. Blanks and/or comments in the data tables
indicate where data could not be obtained.

In the survey, each motor is given a number and this number is shown in the left
most column of each table to enable cross reference. A record has been created for
all 207 motors and the Excel database for this will be made available. Only
information on the 139 motors is included in this report.

A summary of the key motor applications is as follows:

Compressed Air
There are three air compressors situated in building 449. Two compressors are rated
at 110kW, with the third rated at 132kW. None of the compressors have invertor
controls fitted and they are controlled through a Honeywell control panel by way of a
simple on/off switch.

Air Handling Units
There are many AHUs across the site providing conditioned air for normal and clean
room environments. They are all controlled by the site BMS system, and full details
are included in section 4.6. Most fan motors above 11kW are controlled through
invertors which are installed in the electrical cabinets. The invertors have a variety of
manufacturers, although it was not possible to view them all as they were inside
cabinets, some of which could not be opened. All motors are controlled through
pressure requirements managed through the BMS.


Chilled Water
There are three primary chillers serving the site situated in building 449. The chillers
provide cooled water for process and also condenser purposes for both the main
cooling towers and a total of 6 further chillers around the site. Each chiller has a
primary cooling water pump (30kW), and a condenser water pump (45kW). All
motors had soft start control which are monitored through the site SCADA system.

Within building 449, there are a total of five cooling towers, four with 2no 25kW fan
motors, and a newer one with 2no 22kW fan motors. These motors are controlled
through the SCADA system and have 2 stage control only with no invertors or soft
starts. It is understood that the older cooling towers may be replaced in the next
couple of years due to corrosion issues.
There are a further two York chillers situated outside the building which were not
running at the time of the survey even though the external temperatures were
reaching 25C. This is probably due to the fact that the cooling water is used
primarily for processes, and the process load has been slowly declining over recent
years.
From the cooling towers there are three secondary cooling water pumps rated at
90kW each. These serve a cooling water buffer tank and part branches off to serve
the buildings. From the buffer tank, there are a further 2no pumps (75kW) pumping
water around the site. All motors were invertor controlled.
With building 427 there are 2no primary and 2no secondary chilled water pumps
rated at 15kW and 11kW respectively

Hot Water
Three steam boilers situated in building 227 provide steam to air handling units, low
pressure hot water heating circuits, processes and catering and domestic hot water
services. There are four feed water pumps situated in the plant room each rated at
22kW. There are several other pumps within the boilerhouse and also within smaller
plant rooms situated across the site. Motor sizes varied from 15kW to 22kW and had
varied control methods.
There are also three boiler draught fans, used to force air into the boilers to aid
combustion. These motors were rated at 15kW each, and each had invertor controls
fitted. Only one boiler was operating at the time of the survey due to the low demand.
The most significant other plant room around the site is building 427 which has
LTHW preheat and reheat pumps

Processes
There are many processes across the site which require air and liquid. These are
divided into primary processes and secondary processes. The primary processes
includes storage tank pumps, natural gas compression pumps, incinerator related
pumps and borehole water pumps.
4.3.3 Basis of Analysis

The data collected has been analysed to:
Establish the motors efficiencies and rate these against current high
efficiency standards.
Calculate potential return on investments for motor upgrades and/or variable
speed drive applications.
The analysis process and the results are described in detail as follows:


High Efficiency Motors A definition
The industry organisation CEMEP has produced a standard for motor efficiencies,
now widely used in Europe and elsewhere, using the EFF rating scheme - EFF1
being the highest efficiency class. EFF2 is an intermediate level and EFF3
represents all other motors that do not meet the EFF2 level. The CEMEP rating
scheme covers 2 and 4 pole motors from 1.1 to 90kW. There is another standard for
high efficiency motors - WIMES (Water Industry Motor Efficiency Standards). This
standard, defines minimum high efficiency motor percentages for 6 and 8 pole
motors and for motors up to 400kW.

Using these two standards, we have a high efficiency benchmark for 2 and 4 pole
motors from 1.1 to 400kW and 6 and 8 pole motors from 5.5 to 315kW. These
standards are used by the UK Government to define whether products are suitable
for its Energy Technology Product List and therefore qualify for tax incentives.
1

This report will use these standards to benchmark the existing motor asset base.
4.3.4 Global Metrics
Examination of the data yields the following information with an overall perspective:
Quantity Percentage
Number of Motors Surveyed and rating obtained 137 100.0%
Total Installed Capacity (kW) 3782 100.0%
Number of Motors for which data was available to
calculate efficiency and to benchmark 53 38.4%
Number of Motors in High Efficiency Category (EFF1 or
WIMES HE) 9 17.0%
Number of Motors with VSD's installed 12 8.7%
Rating of Motors with VSD's installed (kW) 761 20.1%

An estimate has been made of what the annual electricity consumption of these
motors might be. This has been done using a bottom up method - from individual
consumption estimates for each motor. Using linear extrapolation, the consumption
of the total population of 207 motors rated at 11kW and above is also estimated.
kWh kg CO
2

Estimated annual consumption by motors
11kW (extrapolated to total population) 14,983,681 686,253 6,592,820
Site Electrical Consumption (2007) 41,670,000 1,908,486 18,334,800

Motors consume typically 60% of the electrical energy on an industrial site and this
would indicate that these motors rated at 11kW and above, consume 60% of that
proportion. This seems a reasonable validation, on average, that the running hours
and load factors assumed are conservative. The data and assumptions used for the
above are shown in the table below:

Electricity Cost p/kWh 4.58
kWh to kg of CO2 conversion 0.44
Motor average utilisation factor 0.75
Site annual electrical consumption MWh 41,670
Proportion of electricity consumed by motors 60%

1
See website: http://www.eca.gov.uk/NR/rdonlyres/F0F59A73-26D2-4590-8EF7-
56A87388373F/0/07MotorsandDrives_SingleSpeedMotors.pdf


4.3.5 Efficiency Calculations
Where data has been available and recorded, full load efficiencies have been
calculated and are compared to the CEMEP or WIMES rating schemes see section
4.3.3 for definitions.
Full load efficiencies have been calculated, as follows:

Efficiency % = Rated power x 100
Input power
and Input Power = 3 x voltage x full load current x power factor

The calculated efficiencies are compared with the high efficiency benchmarks
described in section 4.3.3. These benchmarks vary slightly with the number of poles
of the motor. If otherwise not known, a 2 pole motor is assumed.

The table of motors with their efficiencies and the comparison with the relevant
benchmarks are shown in Appendix 7. From this table it can be seen that of the 53
motors for which data was available to calculate an efficiency figure and benchmark,
9 are in classed as high efficiency. The table below shows the full breakdown:
Quantity Percentage
Number of Motors Surveyed and rating obtained 137 100.0%
Total Installed Capacity (kW) 3782 100.0%
Number of Motors for which data was available to
calculate efficiency and to benchmark 53 38.4%
Number of Motors in High Efficiency Category (EFF1 or
WIMES) 9 17.0%
Number of motors to EFF1 9 17.0%
Number of motors to EFF2 8 15.1%
Number of motors to WIMES HE 0 0.0%
Number of motors to EFF3 or WIMES Non HE 36 67.9%
Number of Motors with VSD's installed 12 8.7%
Rating of Motors with VSD's installed (kW) 761 20.1%
4.3.6 High Efficiency Motor Replacement
The following procedure has been used to assess the potential energy saving and
investment cost requirement for a selection of the motors if replaced with a high
efficiency equivalent. From this a prospective return on investment (ROI), based on
simple payback, has been calculated. Results are shown in Appendix 8 for ROIs up
to 10 years.

When viewing the results, the following points must be borne in mind:

Where full data is not available to calculate efficiency, when relevant, the
EFF2/EFF3 boundary rating has been used, in line with CEMEP guidelines.
Results are annotated where this assumption has been made.
Where actual load data is not available, a load factor of 75% is used. Results
are annotated where this assumption has been made.
Full load efficiencies have been used in these calculations which would make
the projected savings conservative. Modern high efficiency motors tend to
have a flatter load/efficiency curve than conventional motors indeed in the
EFF1 class the 75% load efficiency is usually equal or slightly better than the


full load efficiency. In order to allow for this, an adjustment to the efficiency
gain has been made as follows:
o Load factor > 80% 0% increase of gain
o Load factor 60-80% 1.5% increase of gain
o Load factor <60% 3.0% increase gain

The cost and hence ROI take no account of depreciated asset values. If
some of the asset value can be written down, then the return on investment
figures would improve accordingly.

The potential annual saving has been calculated as follows:
Saving = Input power x loading% x annual hours x efficiency gain x cost/kWh

Motor cost is based upon the Brook Crompton price from the GSK preferred supplier
agreement plus an allowance for installation.
The recommendations and potential savings are summarised below:

Investment Cost Potential Savings
Recommendation Capital Revenue kWh kgCO
2
kWh/ ROI
34 Motor Replacements 50,213 164,152 7,518 72,227 3.3 6.7

It is noted that in the above are included recommendations for motors associated
with the cooling towers and it is understood there are plans to replace some of these
towers.
4.3.7 VSD Applications
Examination of the survey data shows that of the 137 motors surveyed, 12 have
variable speed drives fitted, with total rating of 761kW (20%) of the 3782kW total
installed motor rating.
From the survey, a number of motors have been identified as potential applications
for variable speed drives. Results are shown in Appendix 9 for ROIs up to 10 years.
Based upon an average of a 10% reduction in speed, which equates to around 20%
reduction in energy consumed, potential savings are calculated for each motor. The
recommendations and potential savings are summarised below:

Investment Cost Potential Savings
Recommendation Capital Revenue kWh kgCO
2
kWh/ ROI
30 VSD
Applications 167,643 756,760 34,660 332,974 4.5 4.8
4.3.8 Discussion of Recommendations

Motor Data
Obtain missing motor data take opportunities during maintenance and other
intrusive activities to access the rating plates to expand the list of motors that can be
analysed. Prioritise the motors with annual running time 4000 hours.

Intrusive Survey
Selected motors should be monitored to establish actual power consumption and
load cycle. Where motors are in similar applications or in pairs, duplication can be
avoided. A proposed list is shown below.


Motor
Number
Building
Number Building name Description / Application
Motor
Power kW
3 449 Cooling tower compound
Cooling water Pump No.1
Ingersol Dresser 90
4 449 Cooling tower compound
SECONDARY COOLED
WATER PUMP NO.2 75
19 449 AIR COMPRESSOR 2 110
20 449 AIR COMPRESSOR 2 132
22 449 CONDENSER PUMP 45
23 449 CONDENSER PUMP 45
58 436 INCINERATOR ID FAN 90
70 401 PRIMARY MANUFACTURING HTF PUMP MID 45
174 404 COMPRESSOR 90
It should be noted that a number of these motors appear in the list of
recommendations for motor replacement or VSD application.

Motor Replacements - Scheduled
Plan for the replacements identified in Appendix 8. Supplement and amend this list
as further data is obtained.

Motor Replacements Breakdown and New Purchases
Ensure that motor replacements and new purchases are made with a high efficiency
type in accordance with the GSK Motor Management Policy.

Variable Speed Drive Applications
Plan for the VSD applications identified in Appendix 9. Develop the proposals in line
with the priorities indicated. Supplement and amend this list as further data becomes
available. These applications will require further examination to validate the
opportunities and to determine how best to implement them.


4.4 Lighting
It is estimated that lighting accounts for around 9% of electricity consumption on the
site.

There has been a policy of using T8 long life lamps on the site and that these will be
gradually introduced as and when replacement of lamps takes place. Each process
building is responsible for its own maintenance and therefore lamps are replaced
when they can be scheduled other than when they pose a hazard by not providing
light where essential. There appears at this time, no policy for lamp maintenance
therefore replacement and cleaning occurs only when required. The following table
details the energy consumption (excluding gear) for each lamp type:

Lamp type Wattage
600mm T8 fluorescent tube 18
Compact fluorescent 28
SON High Pressure Sodium 250

The average lighting lux levels on the site are shown in appendix 1 which includes a
full breakdown of the lighting survey. A summary of the information is shown below:-

Area Type of area Foyer Corridor Max Min
Building 225 Office 695 300 695 152
Building 224 Office/ Workshop n/a n/a 790 242
Building 445 Office 1500 200 2639 184
Building 468 Restaurant n/a n/a 702 408
Building 427 Laboratory n/a n/a 2065 412
Building 400 Production area n/a n/a 2300 22
Building 444 Contractors Compound n/a n/a 2555 142
Building 403 Warehouse n/a n/a 946 89
Building 425 Drum Store n/a n/a n/a n/a
Building 441 Storage Bays n/a n/a n/a n/a
Building 435 Offices 532 300 996 131
Building 436 Incinerator n/a n/a 1162 187

The recommended lighting levels are shown in the table below:-
Luminance
(LUX)
Nature of Task Example Areas
50 No Detail required Cable tunnels, lifts, service ducts, indoor storage
tanks
50 to 100 Visual task confined to movement
and little perception of detail
Corridors, Bulk stores, changing rooms
100 to 150 Some perception of detail Loading bays, escalators, plant rooms, stores
150 to 200 Constantly occupied interiors where
detail does not need to be perceived
Automatic manufacturing processes, dining
rooms, foyers and entrances
200 to 300 Continuously occupied interiors Goods packing, Libraries, Sports Halls,
Assembly Halls, Workshops, warehouses
300 to 500 Details need to be seen General offices, shops, Labs, Machine shops,
paint shops
500 to 750 Fine detail and colour differences
need to be distinguished
Drawing offices, inspection areas
1000 Difficult visual tasks Electronic component assembly, tool rooms.


4.4.1 Building 225

Building 225 is an administration building in the South East Section of the site. There
are four floors in the building, Ground, First, Second and Third although the Second
Floor is currently not occupied. The installed lamps are a combination of T8
fluorescent tubes in double, triple and quadruple fittings in lengths of 600mm,
1200mm and 1500mm with some compact fluorescent tubes. The recommended
Lux levels were exceeded in some parts of the building.

It is recommended as the building is likely to be vacated in the future that a switch it
off campaign would be the most effective way of achieving savings.
4.4.2 Building 224

Building 224 is single storey and houses offices, conference centre & museum and
Support & Logistics. The office area, conference centre & museum are occupied
from 08:00 until 16:30 Monday to Friday. During the audit the conference centre and
museum were unoccupied with all the lights left on.

The Support and Logistics section operates normal working hours but is available
24/7 for those with access requirements. They operate a system of dual control
which turns half the lights off outside normal working hours. In the warehouse there
is both fluorescent and sodium lamps which allows immediate light in the evening
and overnight when required and is well labelled, as indicated below. There are 2D
CFL fittings which are left on overnight to allow those requiring to use the building
enough light to access the switches, which are well labelled. Overall the lighting
control of the warehouse was well controlled.

The office area has glazing on two sides and therefore there is good natural daylight
available. At the time of the survey, it was a bright sunny day and the internal blinds
were closed with all lights switched on.

It is recommended that staff are encouraged to switch lights off rather than close
blinds to block out natural daylight.
4.4.3 Building 445

Building 445 is a three storey office block with a glass atrium at the entrance on the
north side. The ground floor open plan area appears to be unused at the time of the
survey other than a few cellular offices on the perimeter. The majority of lights are
T5 fluorescent 1200mm which were all on during the survey even though there was
good natural daylight available from the atrium, as can be seen from the photograph


below taken at night. The recorded lux levels were between 1057 and 2639 at the
ground floor and balcony areas. It is clear from these high readings that these light
levels were being achieved from the natural daylight source rather than the light
fittings.

It is recommended that photocells are fitted to the lights on the north side of the
building to take advantage of natural daylight available. It is also recommended that
PIR controls are fitted to washrooms. It is recommended that PIR/PEC controls are
installed in the meeting rooms The Fleet, Loarning 8, The Dartford, Bexely, and the
Kaizen that have occasional use and also have daylight available.
4.4.4 Buildings 468
The restaurant is a catering facility of 180m
2
for all staff. The installed lamps are a
combination of T8 fluorescent tubes in single, double, triple and quadruple fittings in
lengths of 600mm, 1200mm and 1500mm with some compact fluorescent tubes. As
the building was recently built there is already passive infrared technology in
occasionally visited areas such as the toilets. However, it was noted that the catering
staff were not aware that they could turn off lights when leaving the building such as
in the lobby area.

It is recommended that PEC should be installed to take advantage of the glazed west
facing wall.
4.4.5 Building 427

Building 427 is a two storey building of offices and laboratories which is open from
8am until 10pm. The is a combination of 600mm and 1200mm T8 fluorescent lamps
in triple and quadruple fittings with some 1500mm. There is a large roof skylight over
the staircase which provides good natural daylight. At the time of the survey the
lights in the staircase were all on with a recorded lux level of 2065, when switched off
the lux level only dropped to 1962 lux. The corridor areas had lux levels between
216 and 422 lux. This is higher than recommended levels.

It is recommended that PIR/PEC controls are fitted to the entrance lobby, staircase,
The Swanky Meeting Room, Phoenix Suite and the Training Room.


4.4.6 Building 400

Building 400 is a process building and is therefore occupied 24/7. The main process
area has high level glazing providing natural daylight. The majority of lights are
1500mm T8 fluorescent. The entrance and lobby area exceeded recommended lux
levels which were due to the high level of natural daylight available.

It is recommended that PIR/PEC controls are fitted to the entrance lobby and Roxley
meeting room. It is also recommended that PIR controls fitted to the occasionally
visited areas such as the wash rooms, locker room, meeting room and service voids.
Due to the availability of natural daylight it is recommended that dimming PEC are
installed on the south side of the process area.
4.4.7 Building 401

Building 401 is a process area and therefore occupied 24/7 with the lights being
permanently on. The technical offices are only occupied during normal working
hours from 08:00 until 16:30 therefore there is an opportunity to switch lights off when
these areas are not in use.

It is recommended that PIR/PEC controls are fitted to the south facing lobby and
entrance and first floor meeting room, to take advantage of natural daylight. It is also
recommended that PIR controls are fitted in those rooms that are occasionally visited
such as washrooms, locker room, meeting rooms, store rooms as well as the service
void areas. Full details are in the lighting appendix
4.4.8 Building 404

Building 404 is a process building and is therefore occupied 24/7. The main process
area has high level glazing providing natural daylight. The internal stairwell and
corridor exceeded recommended lux levels which, was due to the high level of
natural daylight available.

It is recommended that PIR/PEC controls are fitted to the entrance lobby and PIR
controls fitted to the wash rooms and locker room.


4.4.9 Building 405

Building 405 is a production building on the North Site. As this is a key process
building, some of the lights are controlled through the distribution board and on
permanently. In some of the process areas, employees are in a room for 15 minutes
at a time only but the lights were constantly on. Also, there were some areas such as
the loading bay area where lights were on in one bay but not the other. The lights
were also constantly on in the service voids although these are only visited
approximately once per week and for limited amounts of time. Where the lights are
controllable, a people awareness campaign is an option to reduce energy usage.
There is task lighting in the key process areas on the port holes so although the
rooms themselves had sometimes low light levels, such as 154 lux, the working
plane was adequate. The PPE room was a concern for the employees as the lux
levels were 831-1009; moreover the lights were not separately switched so there is
energy wastage and employee discomfort.

It is recommended that PIR/PEC control is installed in the entrance lobby to take
advantage of natural daylight and PIR controls installed in the washrooms, shower
rooms and service voids.
4.4.10 Building 403

Building 403 is the high bay warehouse for the site with associated administration.
The installed lamps are a combination of T8 fluorescent tubes in single, double, triple
and quadruple fittings in lengths of 600mm, 1200mm and 1500mm with some
compact fluorescent tubes. There has been a re-lamping exercise in this building.

However, several fittings were out and some fittings needed cleaning suggesting that
some maintenance is required. There was some good practice in the Meeting Room
as all equipment and lighting was switched off. However, in some of the offices, it
was noted that lights were on despite them being unoccupied. Also, in some offices,
blinds were shut and lights despite natural daylight availability. The warehouse has
been extended and this was clear from the light fittings in the space. There were a
mixture of high and low bay SONs and some fittings we were unable to identify due
to their age.


It is recommended that a voltage reduction control along with some PIR controls
should be fitted within the warehouse. Voltage reduction controllers will reduce the
electricity consumption to the lamps in non high frequency fittings. Where lamps are
high frequency, the drop in voltage will be compensated by an increase in current
thus mitigating any energy savings. There will be a slight dimming of the fitting but
this should be acceptable due to the current light levels
4.4.11 Building 407

Building 407 is the Grinding and Blending unit and is open 24/7. The lamps
themselves were mainly T8 although there were some T12 in the plant room and
switch room for example. There were some areas of good practice where areas were
unoccupied and lights out, however there were also offices which were unoccupied
with the lights on. Also, lighting was permanently on in the plant room although this
was only really used for daily readings and a walk through.

It is recommended that PIR controls are installed in the washrooms, service voids
and plant room. It is also recommend that old T12 fittings are replaced with T8 long
life fittings in the switch room and plant room 04.


4.4.12 Building 425

Building 425 is the chemical store. Most of these areas were lit and unoccupied.
There were some maintenance issues such as in the drummed solvent store where
some lamps were not working. The lighting in here was mostly T12 fluorescent.

It is recommended that the T12 lamps and fittings are replaced with more efficient T8
long life and that PIR controllers are installed to manage the lighting time more
efficiently. As can be seen from the photograph below the lights are permanently on.

4.4.13 Building 441
Building 441 is the Special Material and Cylinder store. In the main this was a well
managed area as most of the buildings were unlit and unoccupied. However, Q01
was lit and S01 although the fridge itself was unlit.
4.4.14 Building 446 and 447
These buildings were not considered as it is due to be demolished and changed to
CHP.
4.4.15 Building 435
Building 435 is a two storey building occupied by the Environmental Management
Centre which consists of offices and laboratories and is in use 24/7. During the
survey the majority of lights were on even although there was good natural daylight
available. The office area within the reception area had switching that did not allow
local control. On the ground floor 50% of the rooms that were not occupied had
lights on. The meeting rooms on the first floor which were not in use at the time had
all lights off although the corridor lights which had windows were all on. The new lab
area has switches in zones from left to right across the area. The blinds in this area
were closed even although there was good natural daylight available.


It is recommended that the switching in the office area is updated to allow local
switching in the offices at reception. It is recommended that staff are encouraged to
switch off lights when there is good natural daylight available, as indicated.
4.4.16 Building 436
Building 436 is a single storey building for the solids incinerator and is in operation
24/7. The lights at the covered entrance were on although there was sufficient
daylight available. The main lighting is from low bay fitting with SON lamps with
additional 1500mm and 1800mm twin fluorescents and two Hi Bay lamps. The area
is occasionally visited with lux levels internally ranging from 187 lux to 221 lux which
are within recommended guidelines for this type of area.

It is recommended that switches are clearly labelled to allow the entrance lights to be
switched off during daylight hours.


4.4.17 External Lighting

A summary of the external lighting is shown in the table below:-

Area Lamp Type Controls
Building 222 250W Floodlight (4)
58W twin fluorescent tubes (4)
Photocell / timer
Building 224 250W Floodlight (3) Photocell
Building 225
Building 400 250W Floodlights (11)
58W twin fluorescent tubes (17)
Photocell / timer
Buiding 401 250W Floodlights (
Building 403 250W Floodlights (14) Timer
58W single fluorescent tubes (6)
Photocell / timer
Building 425 250W Floodlights (9) Photocell
Building 427 28W Compact Fluorescent (23)
250W Floodlight (8)
Photocell / timer
28W Compact Fluorescent (1)
Photocell /timer
Building 436& 438 250W Floodlights (6)
58W twin fluorescent (14)
58W single fluorescent (6)
Photocell /timer
Building 441 18W twin fluorescent (20)
250W Floodlights (10)
Photocell / timer
Car park Bldg 225 250W Floodlights (8) Photocell/timer
Car park 4 250W Floodlights (3) Photocell

The lights in the car park at the rear of building 225 were noted to be on at 11pm and
should have been controlled by a timer to switch them off at 9pm.


Surveying the outside of the building during the hours of darkness, it is apparent that
the majority of these lights were off where not required within the office areas but that
store areas are on and only occasionally visited throughout the night.

Energy saving recommendations are as follows:-

a) It is recommended that presence detection controls (PIRs) are fitted into
appropriate office accommodation within the site as detailed in Appendix 1:

b) It is recommended that photo electric cell controls are installed as detailed in
Appendix 1

These projects will need to have further design work to ascertain firm costs as wiring
modifications may be required.

c) It is recommended that outside lights have voltage reduction controllers fitted as
detailed in appendix 1. These units have an astronomical clock installed which
will ensure that the lights are turned off during daylight periods.

Savings related to the above measures are estimated at 491,000 kWh ( 22,500)
with an estimated capital expenditure of 62,000. A full breakdown of these
measures is included in Appendix 1.


4.5 Power Quality and Availability
4.5.1 Methodology

All electrical substations on site were visited with a view to establishing the following:
Data on any installed PFC and its status at the time of visit;
Data on installed transformers, such as rating, present tap settings, etc;
Voltage levels at the time of visit, obtained from installed instrumentation;
Load power factor at the time of visit, obtained from installed instrumentation (if
available);
Loading of LV panels at the time of visit, obtained from installed instrumentation.
The types of equipment installed in each building, e.g. process loads, office-type
equipment, etc. This information was obtained from GSK utilities staff on site.

A copy of the site single line diagram is included in Appendix 4 for reference.
4.5.2 Power Factor Correction

Of the 22 transformers on site, 14 have PFC applied to their loads, 7 have no PFC
and 1 is unknown. Of the 14 that have PFC applied, 9 are in service and 5 have
been taken out of service. Full details of the site power factor is included in Appendix
5.

The table below displays the transformers whose PFC has been taken out of service.

Assoc.
Tx No.
PF READING LOAD TYPES
T228-1
ALTERNATED
BETWEEN 0.7
AND 0.9 (LAG)
MIXTURE OF OFFICES AND INDUSTRIAL AREAS WITH ASSOCIATED
TEMP CONTROL PLANT
T422-1 0.82 (AVE)
FEEDS BLDG 401 - PRODUCTION BUILDING - MOSTLY INDUCTIVE
LOADS: PUMPS, AGITATORS, PUMPS, AHU, CHILLERS
T422-3 0.86 (AVE)
FEEDS BLDG 400 - PRODUCTION BUILDING - MOSTLY INDUCTIVE
LOADS: CHILLERS, AHUs, NITROGEN PLANT, DUST EXTRACT EQPT.
LABELLED PFC UNIT 120-
3 (WITHIN BUILDING 422)*
1.0
LV PANEL 422-4: NEW PANEL RETROFITTED TO EXISTING 3x 422 LV
PANELS. RELATIVELY LOW LOADING ( 41A/Ph)
T225-1 0.91
OFFICE TYPE LOADS, SOME AIR HANDLING, LARGE CHILLER
DURING SUMMER MONTHS
*AWAITING INSTALLATION DURING VISIT FOR LV PANEL 422-4?

The following table displays the transformers which have no PFC applied to their
loads.
Assoc.
Tx No.
PF READING LOAD TYPES
T467-1 0.99 T467-1: LARGE MULTI-STAGE CHILLER, SIGNIFICANT LIGHTING LOAD
T467-2
PANEL INSTRUMENTATION
INDICATES ZERO PANEL LOAD
T467-2: TRANSFORMER NOT LOADED DURING VISIT
T469-1 0.973 T469-1: 2x CHILLERS
T469-2 1.0 T469-2: NEGLIGABLE LOAD ( 6A/Ph)
T427-1 0.91
T427-1: PREDOMINANTLY SPECIALISED LAB EQUIPMENT, ALSO
SIGNIFICANT AIR HANDLING LOADS, LARGE CHILLERS, SOME
OFFICES.
T241-1 NO PF METER
T241-2 NO PF METER
T241-1, T241-2: BOILER HOUSE PLANT: VARIOUS PUMPS, FANS,
COMPRESSORS. ALSO GAS TURBINE CONTROLS, UPS FOR SCADA
SYSTEM, WATER TREATMENT PLANT.


The use of variable speed drives (VSDs) has generally increased over the years, due
to their energy saving capabilities. VSDs, by their principle of operation, generate
harmonic currents which can interact with standard types of power factor correction,
causing damage to the PFC. Its likely that the Dartford site has added VSD control
to motors over the years, and possible that PFC originally considered appropriate,
given building load types at the time of their specification, may no longer be suitable.
It is also possible that the five PFC units taken out of serviced may have failed due to
this reason.

As a general rule of thumb, if the amount of non-linear load (of which VSDs can be
considered), compared to the total connected load exceeds 15%, detuning reactors
must be used.
It is therefore recommended that the suitability of PFC units (both in and out of
service) be reviewed, with respect to local load types. Temporary power quality
monitoring, performed either over a week long or snapshot period (if carried out at a
representative time), can be used to determine appropriate types of PFC. Schneider
would be happy to assist you with this task, if required.

Transformers with PFC Taken Out Of Service

From the above table, due to the low power factors recorded during the visit, it is
recommended that the suitability of the PFC connected to the loads of transformers
T228-1, T422-1 and T422-3, be reviewed, with a view to either re-instatement or
modification/replacement.

T422-4 had a relatively low load during the site visit and if this load observed was
representative, the need for the PFC applied to this transformers load to be re-
instated/modified/replaced is not seen as urgent.

Regarding the load of T225-1, although the power factor reading recorded during the
visit was not low (0.91), it should be noted that this equipment was visited on 1
st
May
2008, when its likely that the connected chiller wouldnt have been operating. Once
operating, it expected that the load power factor will reduce, and again, it is
recommended that the suitability of the PFC connected be reviewed, with a view to
its re-instatement/modification/replacement.

Transformers with No PFC installed

From the table above, the same reasoning used for the load of T225-1 can be
applied to the loads of transformers T467-1, T469-1 and T427-1 regarding the
operation of connected chiller loads. Therefore it is recommended that feasibility be
investigated regards the application of PFC to the loads of these transformers.

Based on the loading observed on transformers T467-2 and T469-2, application of
PFC to the loads of these transformers is not required.

There is no PFC applied to the loads of transformers T241-1 and T241-2. It is
assumed that Generator 1 will perform power factor correction for this building, if
paralleled with the mains supply. If this assumption is correct, no further action
regards the application of PFC would be required.


Benefits of PFC

The benefits of improving power factor include:
Energy cost reduction:
If a consumer is being charged for reactive power use;
Possible reduction in a sites maximum demand (see below).
Reduction in circuit currents:
Associated transformer and conductor losses reduced on consumers network
and utility companys networks;
Release of additional network capacity.
CO
2
reduction The BEAMA Capacitor Manufacturers Association calculates
that every kVAr of PFC installed results in a reduction of 160kg of CO
2

generated per year (through reduction of losses on the entire UK transmission
and distribution network).

Note: It is reported that a power factor correction equipment audit and inspection has
recently been undertaken (by others) so some issues stated in this report may be in
the process of being addressed. Therefore, no further information or
recommendations regarding power factor correction will be contained within this
report.
4.5.3 Non-linear Loads/Neutral Conductors

The majority of transformers on site utilise LV neutral conductors rated at 50% of the
cross sectional area (CSA) of the associated phase conductors. In the past, 50%
rated main neutral conductors were frequently specified in buildings before the
widespread use of switched mode power supplies (SMPS). Full details of the data
captured is included in Appendix 6.

SMPSs are used in common office equipment such as PCs, photocopiers, fax
machines, etc. and these devices generate harmonic currents, some of which dont
add vectorally in the neutral conductor (and thus dont cancel each other out as is
the case with linear type loads). This effect results in higher neutral currents than
those anticipated when the network was originally designed.

The table below lists the transformers that utilise 50% rated neutrals and supply
buildings that could contain a high proportion of SMPS-type loads:

TRANSFORMER LOAD TYPES
T228-1
MIXTURE OF OFFICES AND INDUSTRIAL AREAS WITH ASSOCIATED TEMP
CONTROL PLANT
T467-1 LARGE MULTI-STAGE CHILLER, SIGNIFICANT LIGHTING LOAD*
T437-1 MIXTURE OF OFFICES, LABS AND MOTOR LOADS
T427-1
PREDOMINANTLY SPECIALISED LAB EQUIPMENT, ALSO SIGNIFICANT AIR
HANDLING LOADS, LARGE CHILLERS, SOME OFFICES.
T225-1
OFFICE TYPE LOADS, SOME AIR HANDLING, LARGE CHILLER DURING
SUMMER MONTHS
*Electronic ballasts assumed



Of the 22 transformers on site, 14 have PFC applied to the associated main
LV panel, 7 have no PFC and 1 is unknown. Of the 14 that have PFC
installed, 9 are in service and 5 have been taken out of service. It is possible
that PFC originally considered appropriate, given building load types at the
time of their specification, may no longer be suitable. It is also possible that
the five PFC units taken out of serviced may have failed due to this reason. It
is therefore recommended that the suitability of PFC units (both in and out of
service) be reviewed, with respect to local load types.

Due to the low power factors recorded during a site visit, it is recommended
that the suitability of the PFC connected to the loads of transformers T228-1,
T422-1 and T422-3, be reviewed, with a view to either re-instatement or
modification / replacement.

Based on the relatively low loading observed at transformer T422-4 during a site
visit, the need for the installed PFC to be re-instated/modified/replaced is not
seen as urgent. Also, based on the loading observed on transformers T467-2
and T469-2, application of PFC to the loads of these transformers is not required.
If the assumption that Generator 1 is paralleled with the mains supply is correct,
no further action regards the application of PFC to the loads of transformers
T241-1 and T241-2 would be required.

It is recommended that the suitability of the PFC applied to the loads of
transformers T225-1, T467-1, T469-1 and T427-1 be reviewed, with a view to
its re-instatement/modification/replacement.

The benefits of improving power factor could include:
Site energy cost reduction:
Reduction in circuit currents:
UK CO
2
reduction

It is also recommended that true rms power monitoring be performed at the
transformers T228-1, T467-1, T437-1, T427-1 and T225-1 to identify whether
harmonic currents are prevalent in the in the network. Mitigating action and /
or neutral conductor replacement may be required depending on the results
of such surveys.


4.6 Building Controls & Building Management Systems
4.6.1 Regulatory requirements

There are several regulatory requirements relating to pharmaceutical processes that
heating, ventilation and air conditioning should adhere to, primarily in the clean room
environment. Cleanrooms are classified by the cleanliness of their air. This is done
according to ISO 14644-1. This is an international standard, having been adopted by
the European Union in 1999, and the USA in 2001
4.6.2 Description of Building Management Systems (BMS)

The site BMS system is split into four main systems and some stand alone systems.
The systems are either operated by the site FM (Johnsons Controls) or by GSK
themselves for more critical areas. It is understood that building log books arent
currently used for plant room modifications, and it is common for control strategies to
be out of date. This causes plant to be switched to manual which in turn results in
alarms to the BMS system. The plant is subsequently set back to auto which in turn
causes the plant to fail.

The BMS systems can be summarized as follows:

Site Coverage BMS Type Functionality Head end
Boilers, Chillers, Cooling
Water, Borehole Water
SCADA
Honeywell
Monitors only Bldg 225
Building 225 Offices Trend 963 Bldg 225
Building 427 R&D Siemens Visonik
Insight
Bldg 427
Building 435
Environmental
Management
Siemens Visonik
Insight
Monitors Nitrogen meter Bldg 407
Building 445 Offices Siemens Visonik
Insight
Monitors & Controls HVAC
system, LTHW, DHW and
various extract systems
Bldg 407
Building 400 Production Siemens Visonik
Insight
Monitors & Controls AHUs
and extract systems
Bldg 407
Insight
and extract systems
Bldg 407
Building 403 Warehouse Siemens Visonik
Insight
Monitors & Controls DHW
and LPHW and some process
Bldg 407
Insight
and extract systems
Bldg 407
Insight
and extract systems
Bldg 407
Building 422
Switchroom
Siemens Visonik
Insight
Monitors transformer
temperatures only
Bldg 407
Building 222 Fire Station Siemens Visonik
Insight
Monitors and controls AHU,
LPHW and extract systems
None
Building 224 Logistics Siemens Visonik
Insight
Monitors & controls AHU and
DHW
None
Building 468 Restaurant Siemens Visonik
Insight
None


All BMS systems were surveyed except for building 222 and building 468 as there
was a fault with the outstations.

Building 225 Scada Honeywell

This system has a head end in building 225 (Phil Broszeks desk) and monitors the
boilers, chillers, chilled water pumps, cooling towers and the borehole water pumps.
The system does not provide any control to these areas, but alarms will indicate any
problems with the plant. An engineer will then be required to rectify the issue with the
plant which would lead to the plant coming out of fault and the alarm cancelled.

It is understood that the majority of this plant will be decommissioned in the next
couple of years so no recommendations are provided. However, it must be noted that
it is good practice for a BMS to control the plant it monitors as this will rectify any
alarms sooner thus ensuring that there is no unnecessary energy consumed. Also it
will reduce labour costs as engineers will not be required to attend the plant for all
eventualities.

Building 225 Trend 963

A head end is situated in the plant room on the ground floor of building 225. The
system is operated by Johnson Controls although only on an ad hoc basis. Several
anomalies with the system were identified during the survey :

1. Steam enters 2 calorifiers in the plant room controlled via a steam valve. The
valve was 30% open and the secondary pumps from the calorifier were
running with a set point 68C. However the outside air temperature was 23C
so there was no heating requirement in the building. Therefore it is
recommended that the heating is held off when external temperatures reach
18 C.

2. AHU 11 on the first floor has some sensor issues. The air was entering the
coils at 26C, passing through two closed heating coils and one open (100%)
cooling coil. It was leaving this coil still at 26C although the space
temperature was 17.2C. From this it would appear that the supply sensor is
faulty causing the cooling coil to remain open and the room temperature to be
so low.

3. AHU15 had all coils off but supply fans running extract fans were disabled.
It is recommended that people are encouraged to open windows to provide
fresh air rather than have mechanical ventilation. When the coils are all
closed, the fans should be disabled through the BMS.

4. Nine fan coil units (FCUs) situated on the first floor all had closed cooling
coils but all had their fans running. Again it is recommended that people are
encouraged to open windows to provide fresh air rather than have mechanical
ventilation.

5. AHU 38 on the third floor had the heating coil open at 100% with ambient
temperatures reaching 23C. Supply air was entering the space at 37C. It is


recommended that the heating is held off when external temperatures reach
18 C, and the fans are disabled when the coils are closed.

6. AHU 40 on the third floor had the heating coil open at 85%. Supply air was
entering the space at 36C. It is recommended that the heating is held off
when external temperatures reach 18 C, and the fans are disabled when the
coils are closed.

7. Twelve FCUs on the third floor all had fans running. They all had cooling coils
of which only 3 were open. It is recommended that people are encouraged to
open windows to provide fresh air rather than have mechanical ventilation.
When the coils are all closed, the fans should be disabled through the BMS

Building 427 Siemens Visonik

This BMS system is under the jurisdiction of Johnson Controls and is supported by
BAS (Building Automation Systems). It is understood that the system is
approximately 16 years old, and has not had much investment since the installation.
Phil Garland from Johnson Controls analyses this system each morning to ensure
the correct running of the plant.

The following anomalies were identified during the survey:

1. Replace fixed speed fans with invertor controlled fans and control through the
BMS on pressure / temperature requirements ( see section 4).

2. The AHU in G16 extension had both heating and cooling coils open 100%.
However, as seen in the following graphic, it is clear that this is required as
the humidity set point is 45%, and the actual is 64.4%. Therefore the cooling
coil is fully open to dry the air and the heating coil is fully open to reheat the
air:


No ambient relative humidity readings were available on the BMS although the
following chart illustrates the local history:

At the time of the survey (7
th
May) the local humidity levels were around 74%.
Therefore we would expect to see some element of cooling to dry the air. However, it
is recommended that all sensors in this AHU are calibrated as fully opened cooling
and heating coils should not be required at any time.

3. The AHU in the CAD facility has a cooling coil and heating coil both open with
a subsequent steam humidifier open. The cooling coil cools and dehumidifies
the air passed through it. If the air is required to be cooled but is then too dry
then humidification is required. Adversely, if the air is required to be dry but is
then too cool, the heating coil will need to run simultaneously with the cooling
coil. However, there should never be any need for all three to be running as
illustrated:

4. The AHU in Laboratory 3 had one preheat coil fully open with an outside
temperature of 20.1C. However, the temperature after the coil was 13.5C.
There is obviously a problem with this sensor causing the heating valve to be
100% open:


Building 407 Siemens Visonik

The head end for this BMS is situated on the first floor in building 407. This is
operated by GSK production personnel, and supported by BAS. The following
anomalies were apparent during the survey:
1. Building 404 Demin plant ventilation has the heating coil fully open which is
only heating the air by 1C. It is recommended that the sensors are therefore
checked.

2. The AHU on the ground and 1
st
floor, and the AHU for the 2
nd
and 3
rd
floor of
building 404 both have invertors installed on the supply fan motors. However,
they are hardcoded to run at 100%. It is recommended that they are
controlled through pressure / temperature requirements


3. The Heat Reclaim unit in building 404 Demin plant was showing a fault. Upon
analysing the condition of this further, it is understood that this unit has not
run since 28/8/02.

4. The AHU in building 404 workshop had both filters dirty which means that the
fan motors need to work harder to provide adequate pressure and workflow.
Also the humidification was 100% on with the humidification set point at 55%.
The ambient conditions were already at this level so there may be a problem
with the rh sensor

5. Building 404 Annexe supply has the heater battery and humidity running at
100%. The humidity sensor is faulty which is causing this problem. Also, it
appears that there may be a problem with the heating coil as there is only a
small temperature uplift.


6. Building 407 general supply AHU1 and 2 require attention. AHU1 is calling for
a small amount of humidity although the setpoint is achieved. AHU2 is
enabling the cooling coil because the humidity is reaching 100%. This is
obviously incorrect and the sensor requires calibration.

7. Building 407 AHU 3 is also not functioning correctly. It appears that a reclaim
coil is 100% open but due to the fact that this is not required, the cooling coil
is also fully open to provide the correct temperature. There are no issues with
humidity levels as the set point and ambient conditions are similar.


8. Building 401 ground and 1
st
floor AHU has both the reclaim coil and the
heating coil 100% open. However it appears that they are not reaching
temperature. Therefore there is either an error with the feedback loop from
the valve positions, an error with the temperature sensor or a mechanical fault
with both coils. This is also apparent in the 2
nd
and 3
rd
floor AHU although the
heating coil is not on.

Local systems

The three local Siemens Visonik systems in the fire station, restaurant and building
224 are not connected to any head end. Alarms are only identified by the attendance
of a BAS engineer. There was a problem with the control interface on two of these


systems so they could not be interrogated. There are also the following buildings
without any BMS control are as follows:
Building 435
Building 405
Potential energy saving opportunities are as follows:-
- It is recommended that the BMS is extended to include building 434 and
building 405.
- The local BMS systems should be connected to the head end.
- The head ends in both buildings 404 and building 427 should be accessed by
the engineering department. Full procedures including building log books
should be instigated to ensure the correct operation of the systems.
Alternatively, this role can be outsourced to a BMS service provider.
- It is recommended that the control methodology, sensors and feedback loops
are reviewed in all areas highlighted within this section. Furthermore, due to
the fact that a high proportion of the controlled plant was operating
inefficiently, logs of sensors, valve positions and other significant plant
conditions should be instigated and analysed after a period of time. This will
ensure the correct operation of all plant.

Savings associated with the above are extremely difficult to calculate based on the
information available. This is due to the fact that there is no sub meter consumption
information for the areas concerned, and a prolonged period of monitoring of the
mechanical and electrical systems was not undertaken.

However, best practice case studies indicate that around 18% savings can be
achieved through implementing a good BMS system where none previously exists.
Although the BMS systems exist, they are not scrutinized for efficiency so a saving of
9% is estimated.
The following yardsticks (based on UK government statistics) can be used for
estimating heating and cooling usage:

Heating
& Hot
Water Cooling
Fans,
Pumps,
Controls
Good
practice
97 14 30
Air-conditioned,
standard offices
Typical
kWh/m2
p.a. 178 31 60
Good
practice
107 21 36
Air-conditioned,
prestige offices
Typical
kWh/m2
p.a. 201 41 67
Good
practice
220 0 20
General
Manufacturing
Industrial
Building
Typical
kWh/m2
p.a. 320 0 30
For the calculations, it is assumed that the areas with BMS installed are not running
to the optimum efficiency, and are only gaining half of the savings, then energy
savings will be around 9% of the buildings concerned. It is also assumed that the
buildings fall into the typical category of the above matrix.

This would provide energy savings of 135,997kWh or 6,233 (electricity only).


4.7 Voltage Reduction

The audit examined the opportunities for energy savings through voltage reduction at
distribution transformers. The objective was to determine whether and on what parts
of the system a detailed voltage reduction study would be appropriate.

The audit obtained data from existing metering, non intrusive examination of
equipment and consultation with the site electrical engineer in the following format:

Site incoming voltage spot readings and any trend information available
Distribution transformer tapping positions
A general view of the nature of the system and the loads

The above analysis concluded that there was indeed scope for reducing the voltage
at the transformers and it was concluded that a full voltage reduction survey is
necessary. It is anticipated that transformers may be tapped down which will result in
savings in open loop resistive and inductive loads such as incandescent lighting and
oversized uncontrolled motors. This report will be provided separately.


5 Appendices

1. Lighting Survey
2. Glossary of terms
3. Metering Data Capture
4. Single Line Diagram
5. Power Factor Correction data
6. Non Linear loads / Neutral conductors
7. Motor records with efficiencies and benchmarks
8. Motor replacement proposals
9. Variable Speed Drive proposals

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