GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001

DG 1301
Design for Energy Efficiency

GMS Design Guides for Secondary Manufacturing and Consumer Healthcare

Any queries or comments on this Guide should be forwarded to Duncan Livingstone - ETCM

Version Date Reason

1 August 2001 Original issue

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GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001

Contents

1. Definitions of Form of Energy

2. Introduction

3. Architectural Consideration

4. Ventilation and Air Conditioning

5. Energy Recovery Systems

6. De-Humidifiers

7. Chillers, Refrigerants and Cooling Towers

8. Pumps and Pipework

9. Hot Water Services (HWS)

10. Electrical Systems

1. Definitions of Form of Energy

1.1 The objective of this Guide is to promote energy efficiency. As such, all designs should be
based on the following;
 Embodied Energy - The sum of the energy used in the construction of, and consumed
during the manufacture of the component parts of a building.
 Delivered Energy - Energy consumed by the Building
 Primary Energy - All the energy consumed during the generation and distribution of the
delivered energy.
1.2 Project specific requirements, such as initial capital cost, investment criteria, risk of local
inflation and availability should be considered against project objectives defined by GSK
such as, life cycle or revenue costing.
1.3 Good Manufacturing Practice (GMP) prevails. GMP compliance must never be
compromised by energy saving initiatives.
1.4 Normally the design should be optimised on the basis of Initial Capital Cost -versus-
Delivered Energy over a pay-back period of 5years or as agreed with GSK.

2. Introduction
2.1 Energy conservation in general results in reduced running costs, however total operating
costs (including maintenance) are not always minimised. The impact of the energy
conservation techniques considered should be analysed against the defined financial
objectives set by GSK or Local Codes in order to determine those techniques, which are to
be applied.

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GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001

2.2 Techniques should be evaluated separately and in combination. Simple “pay back”
calculations based on the relevant, agreed, proper, accounting criteria should be undertaken.
If these indicate a “pay back” period acceptable to GSK, then a full “Discounted cash flow”
analysis should be undertaken.
2.3 Selection of fuel depends primarily on availability and the current and future forecast fuel
costs. However, where electrical costs per kWh are significantly higher than that of gas,
lowest energy usage is not necessarily the same as lowest fuel costs.
2.4 Energy efficiency features are traditionally regarded as optional refinements that may or may
not be justified individually on the basis of their cost savings. While this may make sense
from the value-for-money point of view, it is not the correct approach for energy efficiency.
2.5 Most energy efficiency features are more effective when they are integrated into the design
rather than a “bolt-on” refinement. However, determination of the true cost of integrated
features can be imprecise.
2.6 The required scope for the evaluation of energy efficiency features should be carried out on a
system by system basis. The cost of the energy evaluation and the cost of how the system
will operate in practice should be included.
2.7 Within GSKs' facilities, the most expensive source of energy is electricity. Of this, motive
power and lighting consume the largest proportions. Energy saving associated with the
particular forms of motive power is covered in the relevant sections of this Guide. Energy
savings associated with lighting and general electrical installations are covered in Section 10
of this Guide.
2.8 As part of the Concept Design the Contractor should provide estimated energy consumption
figures. These should include for maximum, annual and average daily summer and winter
consumption's.

3. Architectural Consideration
3.1. In order to develop a passive (solar), climate-sensitive design the Contractor shall include
consideration of:
3.2. Heating Strategy.
3.2.1.Solar collection:
 transparent elements and total energy transmission
 orientation of building and transparent elements
 opaque elements and thermal capacities
 greenhouse effect
3.2.2.Heat storage:
 direct storage
 indirect storage
3.2.3 Heat conservation:
 reduction of transmission losses
 use of opaque elements
 reduction of infiltration losses
 thermal zoning “heat core” utilisation
3.3. Cooling Strategy
3.3.1.Solar Control:
 shading windows and other apertures from unwanted direct sunlight. Shading should
still permit the maximum benefit to be obtained from the sun’s rays in winter
 reduction of glazing in direction of the maximum solar gains
 application of special glazing, with increased absorption or reflective properties
 consideration of “smart” glazing with properties actively responsive to the intensity of
the solar radiation
 deliberate use of existing, or created, local shading from buildings and vegetation
3.3.2.External gains - unwanted, external heat gains by transmission through the building
envelope should be reduced by:
 insulation

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GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001

 exploiting the property of thermal inertia by designing an appropriately heavyweight

building, which will react beneficially to the diurnal temperature variations
 radiation barriers
 reduction in external surface areas
 reduction in air infiltration
3.3.3.Internal gains:
 realistically anticipating internal heat
 selection of high-efficacy, light sources and other energy- efficient equipment and their
correct positioning
 minimising the need for artificial lighting by designing internal reflective surfaces and
light shelves
3.3.4.Ventilation:
 designing the building to make maximum use of the thermocirculation “chimney effect”,
in order to minimise any requirement for forced ventilation and air-conditioning
 no building should be mechanically ventilated unless this can be justified
 using the wind pressure effect
 natural cooling
 understanding and exploiting the psychological and physiological aspects of human
behaviour, by allowing occupants the maximum practicable control over their local
environment
3.3.5.Day-lighting:
 full consideration of the optimum orientation and geometry of the spaces to be lit
 the location, form and dimensions of the openings through which daylight will pass, and
hence daylight distribution
3.3.6.Occupants Behaviour:
 design features whose functions the occupants can understand and will use to reduce the
building’s energy consumption
 design the building’s spaces to encourage occupants to make energy efficient use of the
building

4. Ventilation and Air Conditioning

4.1. Within GSKs' facilities the most expensive source of energy is electricity. Of this, fan
energy, cooling and lighting consume the largest proportions.
4.2. Every effort should be made to reduce fan energy consumption including:
 confirming that a system is required in the first instance
 providing variable instead of constant airflow system where appropriate
 using inverter drives for fan volume control
 designing airflow distribution systems such that all extremities are on index runs
 if a single index run cannot be avoided then intermediate fans, or separate systems,
should be considered
 AHU's and fans should be located as close as practical to the point of delivery
 ductwork and fittings should be designed and installed to provide lowest practicable
frictional resistance, with minimum balancing requirements
 filter selection should be optimised based on dirty-filter conditions, cost of filters, time
between filters’ change, filter resistance, etc
 areas requiring similar air treatment should be zoned
 extent of ‘out of hours’ adjustment in both temperature and air volume should be
maximised
 fans should be selected to ensure maximum fan efficiencies at all operational duties;
normally efficiencies below 75% will be unacceptable
 exhaust air discharges to atmosphere should not be designed for velocities in excess of
15m/s., dispersal should be achieved, where permitted, by use of taller discharge stacks

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GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001

 fans should be adjusted by pulley change, speed control or pitch angle adjustment to give
optimum performance during commissioning - closing dampers may be used for volume
adjustment of up 10% of the design flow rate
 minimum air change rates that achieve comfort conditions in terms of temperature and
air movement should be used, unless there are specified process requirements such as
fixed-extract or minimum air-change rates that dictate higher air-change rates
 equipment such as safety cabinets that are not constantly in use should have the facility
to be switched off , with a corresponding reduction in air-change rates, subject to
acceptable minima
 ventilation systems should not be used to offset heat gain from equipment such as large
deep-freezers , heat should be removed by direct exhaust or cooled by means of a water-
based system
 ductwork air leakage should be kept to a minimum
 where acceptable, air re-circulation should be used
 full fresh air ‘free-cooling’ based on temperature or enthalpy control should be
considered

5. Energy Recovery Systems

5.1. There are numerous types of energy recovery systems that can be used, ranging from run-
round coils to thermal wheels, and from waste heat recovery, (including flash heat from
condensate) to condensing boilers.
5.2. Energy recovery requires additional capital expenditure with a view to recovering this, in
energy cost savings, over an agreed number of years, generally from 3-10 years.
5.3. It is not intended to review the options available in this Guide, but to provide guidelines for
the consideration of each option.
5.4. The considerations for using heat recovery (HR) coils should include:
 additional plant costs including controls, plant space, electrical cabling, drives, panels,
pumps, pressurisation sets, increased fan duties and commissioning
 realistic costs for maintenance of filters, pumps, glycol concentrations, strainers etc.
 associated plant, capital cost reductions, such as central boilers, pre-heater coils, controls
etc. including the maintenance cost savings
 all projected heat/”coolth” recovery should include for energy consumed by HR
circulation pumps, pressurisation set, extra fan resistances caused by coils/filters, etc.
5.5 Energy recovery systems invariably lead to increased complexity of systems, particularly the
controls. Economic operation, relies on the correct commissioning of all systems.
Inadequate commissioning would lead to the full potential of the system(s) never being
achieved. There should be careful consideration of complexity versus potential savings.

6. De-Humidifiers
6.1 The requirement for Low Relative Humidity (Low RH) requires a high demand for energy.
Minimising this demand can be achieved by the consideration of:
 sensible heat recovery from the reactivation exhaust air to the supply before any heating
coils
 sub-cooling of the condensate from steam coils
 use of the pre-cooler, chilled water (or glycol/water) medium for sensible cooling after
the de-humidifier.
 use of heat reclaim from the reactivation air for terminal re-heat/heating

7. Chillers, Refrigerants and Cooling Towers

7.1. It is GSKs' policy that selection of refrigerants must be restricted to non-CFC’s. Non-CFC
refrigerants may have a lower Co-efficient of Performance (COP) than the ozone depleting
CFC (or HCFC) refrigerants which they were developed to replace. Overall CO 2 emissions
per unit of cooling will therefore be increased.

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GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001

7.2. It follows that selection of chiller type, capacity and refrigerant should be carefully selected
to ensure that the environmental benefits of using non-CFC refrigerants is not negated by the
detrimental effects of increased CO 2 emissions.
7.3. Absorption chillers using steam, gas, or waste heat should be considered. The COP for these
should be >1.0. Energy consumption is significantly greater than for vapour-compression
refrigeration options, but overall fuel costs may be lower due to the type of fuel used.
7.4. For chiller applications in the temperate climates this full load COP for vapour compression
refrigerant water chillers, without ancillaries should not be less than 5.0. This should be
maximised, throughout the range of the machine, by consideration of many factors including
the following:
 minimising compression ratio
 minimising non-useful superheat
 maximising sub-cooling
 using high efficiency compressors
 using latest fully-developed alternative refrigerants that show most suitable efficiency
characteristics
 reviewing rotary compressors that are more efficient than reciprocating machines
 minimising evaporator temperature differential.
7.5. Water-cooled condensers generally give the best overall energy-efficient operation.
However due to the perceived problem of legionella and associated water treatment regimes,
their use must be agreed with GSK.
7.6. Condensers should be located to ensure unrestricted air flows and where two or more are
sited adjacent to each other re-circulation or air starvation should not occur regardless of
wind or building effects.
7.7. If air-cooled chillers are used, they should be packaged units or the components closely
grouped. If water-cooled chillers are used the chiller should be located as close as
practicable to the cooling tower to minimise circuit pressure losses, including cooling tower
losses.
7.8. Energy input to cooling tower fans should be optimised by careful selection of cooling tower.
7.9. The most efficient method of capacity control should be used; hot gas injection should be
avoided. The aim is to choose a system which gives a power reduction as close as possible
to the corresponding decrease in capacity.
7.10. Individual systems should be considered where there are loads at significantly different
temperature requirements.
7.11. Where large, centralised, de-coupled systems are required, careful attention should be given
to the loading/unloading control of the chillers to ensure optimum efficiencies are
maintained.
7.12. In the case of air conditioning chilled water systems, flow temperatures <7°C should be
avoided and, where appropriate, scheduled against ambient temperatures such that higher
flow and return temperatures can be used during cooler weather.
7.13. Chillers should be designed to take full advantage of low condenser water temperatures
when ambient conditions permit.
7.14. With chiller installations, opportunities may arise to recover low grade heat from the
condensers. Increasing the temperature of this low grade heat will decrease chiller
efficiencies. Unless there is a need for low grade heat, condenser heat recovery rarely proves
economic, but should be considered.

8. Pumps and Pipework

8.1. Within GSKs facilities, pumps are a significant consumer of electrical energy.
8.2. Every effort should be made to reduce pump energy consumption including consideration of
the following:
 minimising the number of systems
 providing variable instead of constant fluid flow system

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GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001

 using inverter drives for pump volume control, most cost effective on motors larger
than1kW
 design fluid flow distribution systems such that all extremities are on index runs
if a single index run cannot be avoided then tertiary pumps, or separate systems, should
be provided
 operating pressures and flow resistances should be reduced as far as possible; low-loss
commissioning valves should be used
 systems and pumps should be located as close to the point of delivery. This implies
regional or even local plant
 pipework and fittings should be designed and installed to provide lowest practicable
frictional resistance
 pumps should be selected to ensure maximum efficiencies at all operational duties;
normally efficiencies below 75% will be unacceptable
 pumps should be adjusted by pulley, speed adjustment or impeller change to give
optimum performance during commissioning; closing valves may be used for volume
adjustment of up 10% of the design flow rate.
 Where applicable, heating water temperature should be suitable for economic operation
with condensing boilers.
8.3. Glycol or glycol/water mixtures should be used only where alternative ‘freeze protection’
methods are unsuitable. Where unavoidable the most suitable mix with regards heat transfer,
viscosity, cost and hazards should be reviewed.
8.4. Fluid flow and return temperatures should be as close to ambient as possible, while still
achieving required duty with economically-sized heat transfer equipment.
8.5. In Low Temperature Hot Water (LTHW) systems differential temperatures up to 16C should
be considered.
8.6. Application of ‘out of hours’ adjustment of temperatures should be maximised, e.g. night set-
back.

9. Hot Water Services (HWS)

9.1. Hot water should be generated on an ‘instantaneous’ basis by direct heating. Where this is
used for 'microbial' critical areas, heat maintenance tape should be used on dead-legs in
excess of 2m. Where high demand makes this unsuitable, storage should be provided.
9.2. In HWS systems it is necessary to limit dead-legs to reduce water wastage and minimise the
risk of legionella. This can be achieved by different methods and each should be reviewed in
terms of energy usage:
 central system with pumped return or heat maintenance tape
 local point of use generation
 storage capacity, including piping, should be carefully calculated, with heat-up times to
ensure
 standing losses are minimised
 piping should be routed to minimise dead-legs

10. Electrical Systems

10.1. Motive Power. In addition to the techniques discussed for reducing fan and pump duties,
additional options for reducing electrical consumption are:
 high efficiency motors - give savings above a standard motor in the range of 1 to 3%
for minimal additional cost.
 variable speed drives - when installed on an induction motors give a 50% saving in
electrical consumption at a 20% reduction in speed.
10.2. Lighting - The following should be considered in lighting designs;
 luminaires should be positioned where they provide most effective lighting
 high efficiency discharge lamps should be used where colour rendering is not important

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GMS – Engineering, Technology & Capital Management DG 1301 - Design for Energy Efficiency, Version 1, August 2001


the use of tungsten lamps for general lighting should not be used

high frequency control equipment for fluorescent luminaires should be used

fluorescent lamps should be T5 tri-phosphor type

diffusers should be clear or prismatic type manufactured from UV stabilised acrylic, opal
type diffusers should not be used
 consideration should be given to the use of high efficiency mirrored reflectors
 occupancy sensors should be considered for areas of infrequent use
 daylight dimming facilities should be considered for luminaries adjacent to windows
 manual switches should be installed to ensure that lamps operate according to available
day light and occupation patterns
 external lighting should be zoned/designed to ensure it operates efficiently and only as
required, generally for security and safety purposes
10.3. Power Distribution - The following should be considered in the Power Distribution designs;
10.3.1. Energy consumption meters should be located at all relevant distribution points for
monitoring purposes. Where justified, the outputs should be suitable for connection into the
BMS.
10.3.2. Power Consumption Benchmarks.
 Manufacturing 65 kWh/m2/year
 Offices 72 kWh/m2/year
 Storage/Distribution 30 kWh/m2/year

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