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Previous case study

HVAC CONTROLS OPTIMISATION AT PHARMACEUTICAL MANUFACTURING FACILITY

Client: Global top 10 pharmaceutical company | Location: Puerto Rico | Sector: PHARMACEUTICAL MANUFACTURING

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Previous case study

PROJECT BRIEF

EECO2 identified, following initial energy reviews carried out across both manufacturing sites, that the heating, ventilation and air conditioning (HVAC) and building management system (BMS) were not operating optimally and that efficiency improvements could be realised.
While the HVAC systems were delivering compliant facility temperature and humidity control, the systems were delivering this at an energy expense with failed equipment.
In addition to the energy cost, it was suspected that control devices and readings within the BMS may have been from faulty sensors and valves, often leading to manual interventions to the systems which can reduce the ability of the system to respond efficiently to environmental conditions, both internally and externally.
Our brief therefore included the identification and implementation of remediation work to correct and clear any underlying faults.

METHODOLOGY

The initial step was to identify the necessary actions and develop a plan for enabling remediation work by local contractors.
Where it was verified that mechanical and electrical functionality was correct, the control logic was checked to ensure it matched the needs of the space. Other steps followed to optimise the controls as time allowed, however the focus was on returning as many systems as possible to a stable, automatic operation. The process for identification and remediation of issues was broadly as follows:

  • Check mechanical/electrical functionality
  • Verify control logic is efficient and compliant, modify logic appropriately
  • Check time scheduling setup appropriately
  • Apply deadbands/offsets to temp and humidity
  • Tune control loops to provide robust response
  • Maintain optimum performance – monitor ongoing performance.

SOLUTION

BMS optimisation was achieved via the following:

EECO2 developed the Quality Risk Assessment documentation and worked with the client Quality team to gain approval

Fixing defective mechanical equipment and sensor issues – routine maintenance activity following existing SOP’s

Changing filters and fan belts where required – routine maintenance activity following existing SOP’s

Checking software logic and compliance with original specification and current site requirements

Modifying software logic as required to deliver a more optimised control strategy

EECO2 also monitored system stability and performance pre and post project implementation.

RESULTS

Energy savings identified (per year)

Energy savings identified (per year)

5,847,000 KWH

Energy cost savings identified (per year)

Energy cost savings identified (per year)

$900,000 USD

Emissions reduction (per year)

Emissions reduction (per year)

2,602 tonnes

of CO2

The project defined 3 primary success criteria which were deemed to have been met:
• Improved temperature and humidity control
• Reduced energy consumption
• Improved HVAC system compliance and robustness.
In addition, as the project was delivered while both sites were working live it was imperative that conditions were maintained within quality compliance limits at all times. This objective was met with zero quality compliance environmental excursions.

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