Energy saving in a Reasearch Facility Peter Natkanski.

Energy saving in a Reasearch Facility

Peter Natkanski

The business case for designing a New R&D FacilityThe business case for designing a New R&D FacilityThe Research Biology Center of Novartis Crop Protection in Stein/AGThe Research Biology Center of Novartis Crop Protection in Stein/AG

The business case for designing a New R&D FacilityThe business case for designing a New R&D FacilityThe Research Biology Center of Novartis Crop Protection in Stein/AGThe Research Biology Center of Novartis Crop Protection in Stein/AG

Jost Harr, Ph.D.

R&D Special Projects andPublic Affairs Europe

Novartis Crop Protection AG

Jost Harr, Ph.D.

R&D Special Projects andPublic Affairs Europe

Novartis Crop Protection AG

Decision to build new Research Facility in 1996Decision to build new Research Facility in 1996

Several mergers and acquisitions 1970-Several mergers and acquisitions 1970-1996 1996 Novartis has 5 research Novartis has 5 research sites in Switzerlandsites in Switzerland

Consolidation in preferably one site is Consolidation in preferably one site is desirabledesirable

Contrary to earlier projects, the final one Contrary to earlier projects, the final one had to be accomplished with a had to be accomplished with a veryvery lean budget of CHF 76 Mio (approx. $ 50 lean budget of CHF 76 Mio (approx. $ 50 Mio). Mio).

No compromises on qualityNo compromises on quality

Accommodate the desires and ideas of Accommodate the desires and ideas of users coming from 3 different users coming from 3 different company culturescompany cultures

UsersUsers UsersUsers

Architect Architect Architect Architect

Management Management Management Management

Engineers Engineers Engineers Engineers

Engineers Engineers Architect Architect

ManagementManagement

UsersUsers

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Some extremely safe ways to failure:Some extremely safe ways to failure:

““User requirements are just wishful User requirements are just wishful thinking”thinking”

““An architect’s concepts are just An architect’s concepts are just dreams”dreams”

““Engineering rules are carved in Engineering rules are carved in stone”stone”

““Management will agree to a higher Management will agree to a higher budget”budget”

Some extremely safe ways to successSome extremely safe ways to success

Future users defineFuture users define their requirements their requirements

Team challengesTeam challenges user requirements user requirements

Architects competeArchitects compete with proposals with proposals

Team challengesTeam challenges architect’s lay-out architect’s lay-out

Team reconcilesTeam reconciles budgetary budgetary constraints, user requirements, constraints, user requirements, design, and engineeringdesign, and engineering

Essential activities and facilities identified by usersEssential activities and facilities identified by users

Laboratories & Offices Laboratories & Offices Potting of test Potting of test

plants Climate chambers plants Climate chambers HQ HQ

Basel Test plant rearing Basel Test plant rearing

Greenhouses Greenhouses

Seeding & Potting Seeding & Potting Lab material Lab material

Soil substrates Soil substrates Supply of lab Supply of lab

material Pathogen rearing material Pathogen rearing

Insect rearing Composting Insect rearing Composting

Radiolab. tests Radiolab. tests

Application rooms Application rooms etc. etc. etc.etc. etc. etc.

Grouping of Activities and FacilitiesGrouping of Activities and Facilities

Composting & trashSoil & substrates

HQ BaselSupply of lab mat.

Greenhouse activities:rearing and testing

Climate chambers Laboratories & offices

Seeding & potting

Application of test compounds

radiolab.tests

Insects

Pathogens

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Architectural Translation

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Composing the Project Team: Subobtimal Association

InternalInternal::

Project ManagerProject ManagerProject EngineerProject EngineerUser RepresentativesUser RepresentativesEngineering SpecialistsEngineering SpecialistsPurchasing SpecialistsPurchasing SpecialistsControllersControllersSite Safety OfficerSite Safety Officer………………………………………………

ExternalExternal::

ArchitectArchitectGeneral ContractorsGeneral ContractorsIndividual ContractorsIndividual ContractorsEngineering SpecialistsEngineering SpecialistsConsultantsConsultants…………………………………………………………………………………………......

Composing the Project Team: Optimal Association

External:External:

ArchitectArchitect General ContractorsGeneral Contractors Engineering SpecialistsEngineering Specialists Individual ContractorsIndividual Contractors ConsultantsConsultants

Internal:Internal:

Project ManagerProject ManagerProject EngineerProject EngineerUser RepresentativesUser RepresentativesEngineering Specialists Engineering Specialists Purchasing SpecialistsPurchasing SpecialistsControllersControllersSite Safety OfficerSite Safety Officer

Managing the Project Key Success Factors

Strong linkage of internal and external Strong linkage of internal and external expertise expertise

Involvement of future users from Involvement of future users from beginning of projectbeginning of project

Delegation of responsibilities Delegation of responsibilities

Severe cost control from purchasing Severe cost control from purchasing through entire implementation phasethrough entire implementation phase

Examples for Successful Team Approach

E.U. von Weizsäckers book E.U. von Weizsäckers book

““Factor 4: double wealth with 50% Factor 4: double wealth with 50% input” input”

was a major theme in the projectwas a major theme in the project

Factors influencing energy consumption:Factors influencing energy consumption:

• Building shell (often leaking in industrial Building shell (often leaking in industrial buildings)buildings)• Air-conditioning Air-conditioning • Using or wasting surplus energyUsing or wasting surplus energy• Exaggerated overall cold temperature Exaggerated overall cold temperature requirements requirements • Lab hoods wasting heat via common Lab hoods wasting heat via common building aerationbuilding aeration

Examples for Successful Team Approach

Building shellBuilding shell

• k-value of walls: k-value of walls: 0.3-0.40.3-0.4• k-value of windows: k-value of windows: 1.01.0• k-value overall: approx. k-value overall: approx. 0.70.7

Examples for Successful Team Approach

Air conditioningAir conditioning

Users agreedUsers agreed this this was a non-was a non-

issue!issue!

(Of course, this is (Of course, this is not Florida or Cairo!) not Florida or Cairo!)

Advantage:Advantage: all windows can all windows can be opened.be opened.

Examples for Successful Team Approach

Using surplus energyUsing surplus energy

Several installations and Several installations and processes generate heat processes generate heat that can be used for that can be used for heating from fall to spring.heating from fall to spring.

• Example 1: Growth lamps Example 1: Growth lamps in glasshouses. Heat in glasshouses. Heat is is kept inside kept inside glasshouse glasshouse through energy shield through energy shield

when lamps are on. when lamps are on. Effectiveness:Effectiveness: 50-60 % 50-60 %

Examples for Successfule Team Approach

Using surplus energyUsing surplus energy

• Example 2: Growth lamps Example 2: Growth lamps in in climate climate chambers. Heat is re-chambers. Heat is re-gained and is used in gained and is used in

active active floors/ceilings for heating in floors/ceilings for heating in winter. (Strongly winter. (Strongly supporting supporting regular heating system in regular heating system in lab lab building)building)

Examples for Successful Team Approach

Using surplus energyUsing surplus energy

• Example 2: Growth lamps Example 2: Growth lamps in in climate climate chambers. Heat is re-chambers. Heat is re-gained and is used in gained and is used in

active active floors/ceilings for heating in floors/ceilings for heating in winter. (Strongly winter. (Strongly supporting supporting regular heating system in regular heating system in lab lab building)building)

Users agreed to open Users agreed to open ceilingsceilings required for required for temperature temperature exchange. Fringe benefit: exchange. Fringe benefit: easy easy access to access to infrastructure! infrastructure!

Examples for Successful Team Approach

Using surplus energyUsing surplus energy

• Example 3. Cheapest and Example 3. Cheapest and most most ecological way to ecological way to produce cold: produce cold: Ammonia Ammonia compressors produce compressors produce ice; brine pipes transport ice; brine pipes transport cold cold to anywhere in facility. to anywhere in facility. Advantage:Advantage: produce iceproduce ice

with with cheap electricity at cheap electricity at night or night or when when heat needed!heat needed!

Disadvantage:Disadvantage: coldest coldest temperature guaranteed is temperature guaranteed is

+4+4ooCC

Examples for Successful Team Approach

Using surplus energyUsing surplus energy

• Example 3. Cheapest and Example 3. Cheapest and most most ecological way to ecological way to produce cold: produce cold: Ammonia Ammonia compressors produce compressors produce ice; brine pipes transport ice; brine pipes transport cold cold to anywhere in facility. to anywhere in facility. Advantage:Advantage: produce iceproduce ice

with cheap electricity with cheap electricity at night at night or or when heat when heat needed!needed! Disadvantage:Disadvantage: coldest coldest temperature guaranteed is temperature guaranteed is

+4+4ooCC

Users agreed to min. +4Users agreed to min. +4ooC C (where lower temps. (where lower temps.

required: local required: local solutions )solutions )

Exasmples for Successful Team Approach

Reducing energy lossesReducing energy losses

• Example 4. Lab hoods are energy Example 4. Lab hoods are energy waste machines! Normally hooked waste machines! Normally hooked to central aeration system: to central aeration system: continuous loss of heat in winter.continuous loss of heat in winter.

Users agreed to slightly less Users agreed to slightly less efficient but safe individual hoods. efficient but safe individual hoods. 25% fresh air, 75% recycled 25% fresh air, 75% recycled (filtered) air. (filtered) air. Can be turned off Can be turned off if not in use.if not in use.

Energy loss reduced >75%!Energy loss reduced >75%!

Reasons for success of Project Team

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Reason for success of Project Team

Internal expertise in key technical areasInternal expertise in key technical areas Internal best-of-class purchasingInternal best-of-class purchasing Internal rigid cost controlling Internal rigid cost controlling Internal continuous challengeInternal continuous challenge Internal rigid time controllingInternal rigid time controlling Involvement of contractors in Project TeamInvolvement of contractors in Project Team Involvement of future usersInvolvement of future users Show-piece function of projectShow-piece function of project

In a nutshell success came through..

Amalgamating internal and external Amalgamating internal and external forcesforces

Reaching consensus instead of Reaching consensus instead of compromise compromise

Decision making: Decision making: even wrong or suboptimal decisions even wrong or suboptimal decisions were the were the result of thorough result of thorough discussions discussions

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Engineers Engineers

ManagementManagement

Architect Architect

UsersUsers

Engineers Engineers

ManagementManagement

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Architect Architect

The Result