Pharmaceutical Giant Achieves Yearly Savings of $1.2 Million Across Three Sites and Streamlines Vendor Relationships
September 25, 2015
In a commendable move towards energy efficiency and sustainability, MPC has successfully implemented Cimetrics' Analytika Pro solution to optimize its HVAC and process systems. This innovative approach has led to substantial energy savings, improved reliability, and reduced operations and maintenance (O&M) costs.
The journey began with the detection of a pneumatic actuator leak in MPC's building HVAC systems. Cimetrics, in collaboration with MPC facilities personnel, promptly addressed the issue, and also worked on optimizing the discharge air temperature setpoint.
Continuous Commissioning and Automated Fault Detection
At the heart of the Analytika Pro solution is its continuous commissioning and automated fault detection capabilities. The system employs real-time data monitoring, automated fault detection and diagnostics, and an early warning system to identify problems early and enable prompt corrective actions.
Energy Use and Performance Analytics
The solution also provides energy trend analysis, benchmarking, and optimization suggestions to help MPC identify inefficiencies and opportunities for savings.
Root Cause Analysis
Analytika Pro goes beyond flagging symptoms by analysing data correlations and diagnosing the underlying root causes of faults and inefficiencies, allowing MPC to prioritize repairs and modifications that will have the most significant impact on energy and reliability.
Enhanced Visibility and Reporting
The system offers user-friendly dashboards and automated reporting, providing MPC with valuable insights into system health, energy use, and fault status.
Predictive Maintenance Support
By predicting equipment degradation or failure risks, the system helps MPC transition from reactive to predictive maintenance, reducing downtime and maintenance costs while extending equipment life.
Integration with Existing Control Systems
Analytika Pro integrates seamlessly with a wide variety of building automation and industrial control systems, leveraging MPC's existing data infrastructure without requiring major new capital investments in hardware.
The Impact
By using Analytika Pro's continuous fault detection, root cause diagnostics, energy analytics, and predictive maintenance insights, MPC can better monitor and optimize their HVAC and process systems. This leads to energy savings, improved reliability, and reduced O&M costs.
The systems monitored included 351 air handling units, 180 chilled water and hot water pumps, 68 chillers, 40 cooling towers, and more than 2,500 terminal units. The simple payback for these energy savings is less than 7 months.
The fault that was initially detected was not detected on-site but was detected by Analytika algorithms and corrected, resulting in annual energy savings of $46,731 and an annual carbon emissions reduction of 404 metric tons.
MPC's energy savings amount to $1.27 million per year, which is 5% of its total annual utility cost. The net present value of these energy savings is $1.29 million. MPC achieved an annual CO2 emissions reduction of 10,325 metric tons, equivalent to taking 2,174 cars off the road.
Over 1,000 Analytika software algorithms were used to identify opportunities to reduce energy consumption, improve reliability, and reduce operations and maintenance costs.
MPC's commitment to sustainability is evident in its sustainability policy, which aims to reduce energy consumption by 25% by 2020 and water consumption across its supply chain by 20% by 2020. The success achieved with the Analytika Pro solution is a significant step towards achieving these goals.
The Analytika Pro solution, with its abilities in continuous commissioning, energy analytics, and predictive maintenance, enhances MPC's environmental-science efforts by effectively monitoring and optimizing HVAC and process systems, leading to substantial energy savings in the realm of finance, as indicated by a simple payback of less than 7 months and an annual reduction of utility costs by $1.27 million. The technology incorporated within the system has also demonstrated the potential to reduce carbon emissions by approximately 10,325 metric tons, equal to taking 2,174 cars off the road, showcasing MPC's business strategy in aligning with environmental concerns.
