Energy Management at Jealott’s Hill Owen Everall Site Engineering and Facilities Manager 17 th July 2014 Classification: Internal Use Only Classification: PUBLIC
Energy Management at Jealott’s HillOwen EverallSite Engineering and Facilities Manager
17th July 2014
Classification: Internal Use Only
Classification: PUBLIC
2
Introduction
Classification: PUBLIC
• Jealott’s Hill Site• Jealott’s Hill Infrastructure Legacy• Maintenance Strategy• Energy Management
• Energy Metrics (Consumption and Cost)• Electricity Management• Gas Management
• Case Study on B100 Boiler System• Associated Benefits• Summary• Close
3
Jealott’s Hill International Research Centre, Brack nell
Classification: INTERNAL USE ONLY
4
The White House – the first laboratory built in by I CI in 1928
Classification: PUBLIC
5
…the site has grown since then…
…the site was established in 1927 and there has been a farm here for centuries
Classification: PUBLIC
6
Jealott’s Hill today
Jealott’s Hill site is 60 acres with a buildings footprint 65,000 m² comprising offices, labs, glasshouses, restaurant, gym, IT server building…
An international employee base of 850 staff involved in a range of science activities related to world agriculture
Classification: PUBLIC
We have the largest glasshouse research complex in Europe at 4,000m2
7
…contemporary working environment…
Classification: PUBLIC
8 Classification: INTERNAL USE ONLY
Jealott’s Hill Infrastructure Legacy
9
Jealott’s Hill Infrastructure Legacy
…too expensive to operate…
• Johnson Controls commissioned R&D Building Maintenance Benchmark Data
• Jealott’s Hill operating at 2½ times the cost of majority of our peers
Classification: PUBLIC
10
Jealott’s Hill Infrastructure Legacy
…too expensive to operate…
…out of control…
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
kVA
• Frequently throughout the summer of 2004 the site limit of 5MVA was being breached
• Led to a project being initiated to reinforce the capacity to 7.5MVA at a cost of £500k
Classification: PUBLIC
5MVA electrical
capacity being breached
11
Jealott’s Hill Infrastructure Legacy
…too expensive to operate…
…out of control…
…over capitalised…
• Many cases where too much plant has been installed resulting in high maintenance cost
and poor efficiencies
Classification: PUBLIC
12
SustainablePlant
SimpleProcess
SafePeople
Maintenance Strategy
Classification: PUBLIC
13
Maintenance Strategy
Safe People • minimise maintenance routines (e.g. direct drives), • reduce operational parameters (i.e. temperatures, pressures),• eliminate plant
Simple Process(es) • waste• site operating procedures• out of hours call outs• control loops
Sustainable Plant • maximise value add at project stage (capital investment)• maximise service delivery opportunity (ability to control)• minimise intervention post installation (maintenance)• minimise impact on environment
Classification: PUBLIC
Sustainable
Simple
Safe
14
Maintenance Strategy
Safe People • minimise maintenance routines (e.g. direct drives)• reduce operational parameters (i.e. temperatures, pressures)• eliminate plant
Simple Process(es) • Waste• Out of Hours Call Outs• Building Services Control
Sustainable Plant
• maximise value add at project stage (capital investment)• maximise service delivery opportunity (ability to control)• minimise intervention post installation (maintenance)• minimise impact on environment
Classification: PUBLIC
Sustainable
Simple
Safe
15
Waste Management in 2004
• No recycling
• 38 waste streams identified
• Using 12 waste contractors
• Only 8% of site waste processed
• £1000 per week in maintenance
• £1000 per week in fuel
• 3 tonnes of fuel/tonne of waste burnt
Classification: PUBLIC
Sustainable
Simple
Safe
16
Waste Management
● 2006
- Ceased on site incineration
- Total Waste Management Contract
- Recycling rate approximately 15%
Glasshouse soil recycling June 2009
Classification: PUBLIC
Sustainable
Simple
Safe
17
Out of Hours Call Outs
0
200
400
600
800
1000
1200
2004 2013
Classification: PUBLIC
Sustainable
Simple
Safe
18
Out of Hours Call Outs
0
200
400
600
800
1000
1200
2004 2013
90% reduction
Classification: PUBLIC
Sustainable
Simple
Safe
19
Building Services Control
Classification: PUBLIC
Sustainable
Simple
Safe
20
B103 40ºC Walk In Stability Cabinet
35
36
37
38
39
40
41
42
43
44
45
1
78
15
5
23
2
30
9
38
6
46
3
54
0
61
7
69
4
77
1
84
8
92
5
10
02
10
79
11
56
12
33
13
10
13
87
14
64
15
41
16
18
16
95
17
72
18
49
19
26
20
03
Control with proprietary
control system, wasting energy
and giving poor performance
Classification: PUBLIC
Sustainable
Simple
Safe
21
35
36
37
38
39
40
41
42
43
44
451
79
15
7
23
5
31
3
39
1
46
9
54
7
62
5
70
3
78
1
85
9
93
7
10
15
10
93
11
71
12
49
13
27
14
05
14
83
15
61
16
39
17
17
17
95
18
73
19
51
20
29
21
07
21
85
22
63
23
41
24
19
24
97
25
75
26
53
27
31
28
09
28
87
29
65
30
43
31
21
31
99
32
77
33
55
34
33
35
11
35
89
36
67
37
45
38
23
39
01
B103 40ºC Walk In Stability Cabinet
Control with BMS giving
good control and matching
energy input to losses
Door being opened!
Classification: PUBLIC
Sustainable
Simple
Safe
22
Maintenance Strategy
Safe People
• minimise maintenance routines (e.g. direct drives),
• reduce operational parameters (i.e. temperatures, pressures),
• eliminate plant
Simple Process(es)
• Waste
• Out of Hours Call Outs
• Building Services Control
Sustainable Plant
• minimise maintenance requirement (simple, safe, reliable)
• minimise impact on environment (efficient)
• maximise opportunity at project stage (specify what you want)
Classification: PUBLIC
Sustainable
Simple
Safe
23
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
Classification: PUBLIC
24
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
Classification: PUBLIC
25
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
£-
£500,000
£1,000,000
£1,500,000
£2,000,000
£2,500,000
£3,000,000
Gas Electricity
2004
£440
k £1,2
50k
Classification: PUBLIC
26
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
£-
£500,000
£1,000,000
£1,500,000
£2,000,000
£2,500,000
£3,000,000
Gas Electricity
2004
2013
£560
k
£1,8
20k
Classification: PUBLIC
27
Gas and Electricity Consumption and Cost
kWhrs
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
45,000,000
Gas Electrcity
2004
2013
£-
£500,000
£1,000,000
£1,500,000
£2,000,000
£2,500,000
£3,000,000
Gas Electricity
2004
2013
2013
£1,2
10k
£2,9
20k
Classification: PUBLIC
28
Electricity
Classification: PUBLIC
29
Average Hourly Data December (kWhrs)
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
2004
Classification: PUBLIC
30
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
Classification: PUBLIC
31
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
Classification: PUBLIC
32
Inverter driven water distribution pump
Classification: PUBLIC
33
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
Classification: PUBLIC
34
Demand led Control Strategies rather than time enab led
Time
Time Enabled Control
Supply
Classification: PUBLIC
35
Demand led Control Strategies rather than time enab led
Time
Time Enabled Control
Supply
Classification: PUBLIC
36
Demand led Control Strategies rather than time enab led
Time
Ove
rsup
ply
Time Enabled Control
Supply
Classification: PUBLIC
37
Demand led Control Strategies rather than time enab led
Time
Ove
rsup
ply
Time Enabled Control
Time
Demand Enabled Control
Supply
Classification: PUBLIC
38
Demand led Control Strategies rather than time enab led
Time
Ove
rsup
ply
Time Enabled Control
Time
Demand Enabled Control
Supply
Classification: PUBLIC
39
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux, BMS)
Classification: PUBLIC
40
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux, BMS)
- Rationalise plant (air compressors, intermediate pumps,...)
Classification: PUBLIC
41
Rationalise Air Compressors
Classification: PUBLIC
42
Rationalise Air Compressors
Classification: PUBLIC
43
Identify where pumps are not needed…
Classification: PUBLIC
44
…and remove them…
Classification: PUBLIC
45
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux)
- Rationalise plant (air compressors, intermediate pumps,...)
- LED Lighting
Classification: PUBLIC
46
LED Lighting in corridor, office, breakout and labo ratory spaces
Classification: PUBLIC
47
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux)
- Rationalise plant (air compressors, intermediate pumps,...)
- LED Lighting
- Integrating plant onto the BMS
Classification: PUBLIC
48
B170 Central Research Dispensary
Stable 24/7 operation
Providing an environment for 900,000 compounds
Classification: PUBLIC
49
B170 Central Research Dispensary Cooling
• Two sources of cooling;
• Chilled water controlled by BMS
Classification: PUBLIC
50
B170 Sample Store Chilled Water to AHU
Classification: PUBLIC
51
B170 Central Research Dispensary Cooling
• Two sources of cooling;
• Chilled water controlled by BMS
• 8 DX split systems stand alone, on 24/7 under own control
Classification: PUBLIC
52
B170 Sample Store DX Split Systems
Classification: PUBLIC
53
B170 Central Research Dispensary Cooling
• Chilled water controlled by BMS
• 8 DX split systems stand alone, full 24/7 under own control
• Integrated the two cooling systems to work in harmony
under the control of the BMS
• Improved control of plant to prevent heating and cooling systems from fighting each other
Classification: PUBLIC
54
B170 Sample Store DX controlled by BMS
Classification: PUBLIC
55
B170 Average Weekly Electrical Consumption
0
5,000
10,000
15,000
20,000
25,000
2012 2013
44% saving (£50k pa)
Classification: PUBLIC
56
Energy Management at Jealott’s Hill
● Electricity
- Review running times of plant
- Install inverter driven motors for pumps
- Demand led control strategies rather than time enabled strategies
- Lighting control (internal & external) (PIR, Microwave, Lux)
- Rationalise plant (air compressors, intermediate pumps,...)
- LED Lighting
- Integrating plant onto the BMS
- Preventing heating and cooling plant from fighting each other in Controlled Environment Rooms
Classification: PUBLIC
57
B130 Controlled Environment Rooms
Classification: PUBLIC
58
0
20
0
40
0
60
0
80
0
10
00
12
00
14
00
16
00
18
00
20
00
01-Jul
02-Jul
03-Jul
04-Jul
05-Jul
06-Jul
07-Jul
08-Jul
09-Jul
10-Jul
11-Jul
12-Jul
13-Jul
14-Jul
15-Jul
16-Jul
17-Jul
18-Jul
19-Jul
20-Jul
21-Jul
22-Jul
23-Jul
24-Jul
25-Jul
26-Jul
27-Jul
28-Jul
29-Jul
30-Jul
31-Jul
01-Aug
02-Aug
03-Aug
04-Aug
05-Aug
06-Aug
42
% sa
vin
g in
en
erg
y re
sultin
g in
£2
3k
pe
r an
nu
m
B130 D
aily Electrical C
onsumption P
re and Post C
E
Control M
odifications 2012Ene
rgy saving
Classification: P
UB
LIC
59
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
2004
2013
Average Hourly Data December (kWhrs)
Classification: PUBLIC
60
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
2004
2013
Average Hourly Data December (kWhrs)
Classification: PUBLIC
Energy saving
61 Classification: PUBLIC
Gas
62
Site Boilerhouses by Consumption (kWhrs)
Confidential: Internal use only
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
B100 B23 B110 B167 B101 B170 B88 B161 B173
2004
32MW installed capacity
Classification: PUBLIC
63
Site Boilerhouses by Consumption (kWhrs)
Confidential: Internal use only
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
B100 B23 B110 B167 B101 B170 B88 B161 B173
2004
2013
16MW installed capacity
Halved the boiler capacity
Classification: PUBLIC
64
Site Boilerhouses by Consumption (kWhrs)
Confidential: Internal use only
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
B100 B23 B110 B167 B101 B170 B88 B161 B173
2004
2013
Case study
Classification: PUBLIC
65
B100 Physical Sciences Laboratory 16,000m 2
Classification: PUBLIC
approx. 300 fume cupboards
66
B100 Original Boiler Installation 10MW
Boi
ler
4
Boi
ler
3
Boi
ler
2
Boi
ler
1
• Single circuit
• Constant volume
• BMS enable only
• Temperature control on return of boilers
• Operating at 120ºC
T
Heating Pump
Classification: PUBLIC
Controlling at 120ºC
120ºC 120ºC 120ºC120ºC
67
Original Boiler Installation 10MW
Classification: PUBLIC
68
Heating Pumps
• Belt driven
• Fixed speed
• Difficult access
• Runs 24/7
• Costs >£30k pa to run
Classification: PUBLIC
69
Heater Battery 3 Port Valve Arrangement
Heater Battery 3 Port Valve
Double Regulating Valve
• All of the boiler water flows all of the time (constant volume system)
Unused water flows through bypass
Classification: PUBLIC
70
B100 Gas Consumption in 2004
Classification: PUBLIC
71
B100 Hardware Modifications
Boi
ler 2
Boi
ler 1
P LOW
LO
SS
HE
AD
ER
T
Primary Heating Pump
Secondary Heating Pumpcontrolled via VSD and Pressure Sensor
Hydraulic freedom via Low Loss Header
Resited temperature control point
Demand side Supply side
Classification: PUBLIC
82ºC
72
2 Boilers removed (5MW)
Classification: PUBLIC
73
Modulating Burner Controls via BMS
• Firing rate set by BMS based on demand from the building
• Reduces the number of times a burner is fired thus improving efficiency
Classification: PUBLIC
74
B100 Secondary Heating Pumps
• Direct drive
• Inverter speed control
• Variable duty
• Easy access
• Operating at 82°C
• Runs on demand
Classification: PUBLIC
75
B100 Immersion Heaters for Domestic/Process Hot Wat er
Classification: PUBLIC
76
Intermediate Heating Calorifier
Classification: PUBLIC
77
Intermediate Heating Calorifier removed
Classification: PUBLIC
78
Variable Air Volumes in selected Laboratories
Classification: PUBLIC
79
Heater Battery 2 Port Valve Arrangement
Heater Battery 2 Port Valve
• Only boiler water that is required is supplied (variable volume system)
No wasted water
Classification: PUBLIC
80
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for outside air temperature)
Classification: PUBLIC
81
Compensated Boiler Flow Temperature Control
0
5
10
15
20
25
80 80 80 80 80 80 80 81 82 83 84 85 86 87 88 89 90 90 90 90 90
Out
side
Air
Tem
pera
ture
Boiler Flow Temperature
Classification: PUBLIC
As outside temperature falls we increase boiler flow temperature
82
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for outside air temperature)
● Unoccupied Strategy
- Lab AHU controls ‘night temperature setback’ to provide fabric protection
Classification: PUBLIC
83
Night Temperature Setback
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Night Temperature Setback
time
Classification: PUBLIC
Energy saving
84
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for outside air temperature)
● Unoccupied Strategy
- Lab AHU controls ‘night set back temperature’ to provide fabric protection
- lower fabric set point determined by dew point control
Classification: PUBLIC
85
Dew Point Control for Unoccupied Time Zone
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Lower night setback
temperature
where conditions allow
avoiding dew point
time
Classification: PUBLIC
Additional
energy saving
86
Software Control Strategies Employed
● Variable temperature control at boiler flow (compensated circuit for outside air temperature)
● Unoccupied Strategy
- Lab AHU controls ‘night set back temperature’ to provide fabric protection
- lower fabric set point determined by dew point control
● Occupied Strategy; set point is based on ambient outside temp and is also influenced by lux level
Classification: PUBLIC
87
Lux Control
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Lower day temperature
when sun shines
time
Classification: PUBLIC
Energy saving
88
B100 Gas Consumption after modifications 51% reduct ion
Classification: PUBLIC
Energy saving
89
Normalised Gas Consumption (space and temperature)
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
40,000,000
2004 2006 2008 2010 2012 2014
69% reduction
Classification: PUBLIC
90 Classification: PUBLIC
Associated Benefits £
91
Jealott’s Hill Water Consumption (Tonnes)
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
160,000
180,000
200,000
2004 2014
64% reduction
Classification: PUBLIC
£
92
Building Maintenance Costs reduced 71%
£-
£500,000
£1,000,000
£1,500,000
£2,000,000
£2,500,000
£3,000,000
£3,500,000
£4,000,000
£4,500,000
£5,000,000
2004 2013
71% reduction
Classification: PUBLIC
£
93
Summary
• A robust Engineering Maintenance Strategy will deliver
� reduced utility consumption as well as…
� reduced operational risk (safer)
� better building services control (simpler)
� reduced operational maintenance costs (sustainable)
Classification: PUBLIC
94
Any questions?
Thank you
Classification: PUBLIC