Energy & Sustainable Design Build Green Is a Sustainable cgmp Manufacturing Facility Achievable?

Transcription

1 Energy & Sustainable Design Build Green Is a Sustainable cgmp Manufacturing Facility Achievable? Presentation for ISPE Annual Meeting Bernie Friel, PE - Genesis Terry Jacobs, AIA - Jacobs/Wyper, Architects Orlando, Florida November 5, 2006

2 Building Sustainability Challenge Can a cgmp Manufacturing Facility be designed to achieve LEED Certification? Methodology A. Design a mock cgmp Solid Dose Manufacturing Facility B. Score the facility utilizing LEED criteria C. Summarize findings

3 Building Sustainability Background Statistics In 1999, 16% of the world s population consumed 80% of its natural resources. The United States, with 4% of the world s population, consumed 25% of the world s natural resources. (World Bank) Buildings in the US dominate energy consumption, either directly by way of the structure s operation, or indirectly by way of the building s impact on patterns of land development and transportation. Buildings consume 1/3 of total US energy needs and 2/3 of its total electricity output.

4 Mock Facility Greenetech Pharma Facility: 131,000 SF Mock cgmp Manufacturing Facility ISPE cgmp Sustainable Facility Shipping/Receiving Warehouse Manufacturing Administration Central Plant QC Laboratory Packaging Support

5 Building Sustainability Site: Located on an existing site near public transportation

6 Design Criteria

7 Major Infrastructure Systems Cooling System - (2) 500 Ton Chillers/Cooling Towers Heating System (2) 180 HP Steam Boilers & 3,300 MBTU/H Hot Water System 3,000 kva Sub-Station 500 kw Emergency Generator (14) Air Handling Systems 210,000 CFM

8 LEED Categories Sustainable Sites (8 credits / 14 points) Water Efficiency (3 credits / 5 points) Energy and Atmosphere (6 credits / 17 points) Materials and Resources (7 credits / 13 points) Indoor Environmental Quality (8 credits / 15 points) Innovation in Design (2 credits / 5 points) LEED Certification Levels: Certified Silver Gold Platinum Indoor Enviornmental Quality 22% Innovation in Design 7% Sustainable Sites 20% Water Efficiency 7% Materials / Resources 19% Energy / Atmosphere 25%

9 LEED Points Achieved Sustainable Sites: 7 points achieved (14 point maximum) Prerequisites - Erosion control plan Public Transportation Access- ½ mile of existing. Bicycle Storage and Changing Rooms Provided. Parking capacity does not exceed minimum local zoning requirements. Parking for 5% for fuel efficient vehicles. Site Development/ restore habitat. Use of ENERGY STAR roof compliant, high reflective and high emissive roofing. Interior/Exterior Lighting.

10 LEED Points Achieved ISPE Water Efficiency 3 points achieved (5 maximum) Prerequisite: None Water Efficient Landscaping No Irrigation Reduce Potable Water Use by 50% (Exclude process water requirements)

11 LEED Points Achieved ISPE Energy and Atmosphere 4 points achieved (17 points maximum) Prerequisite: Fundamental Building Commissioning Minimum Energy Performance Fundamental Refrigerant Management Enhanced Commissioning Optimize Energy Performance ( 10.5 %?) Enhanced Refrigerant Management Purchase Green power (35 %) Measurement and Verification

12 Lighting Design

13 Electrical Energy Loads (KW) CA & Cold Storage 11.1% Lights 7.6% HW Pump 0.4% Equipment 22.2% Cooling System 39.2% AHU 14.5% EF/RAF 4.4% RF 0.7%

14 Energy Usage Cost Heat & Humidification 20.9% Lights 3.9% Equipment 11.4% Cold storage 5.9% HW Pumps 0.5% Cooling 11.6% Data Ctr. 10.4% AHU Admin 2.1% AHU Mfg 33.3%

15 LEED Points Achieved ISPE Materials and Resources: 4 Points achieved (13 Maximum) Prerequisite: Storage and Collection of Recyclable Construction Waste Management- Divert 50% from disposal Construction Waste Management- Divert 75% from landfill 10% Regional materials Certified wood

16 LEED Points Achieved ISPE Indoor Environmental Quality: Points 14 points Achieved (17 maximum) Prerequisite: Minimum IAQ Performance Environmental tobacco smoke control Outdoor Air Delivery Monitoring Increased Ventilation Construction IAQ Management Plan During Construction Construction IAQ Management Plan before occupancy Low emitting materials; adhesives and sealants Low Emitting materials, carpet systems Low Emitting materials; agri and wood products

17 LEED Points Achieved ISPE Indoor Air Quality: Points 14 points Achieved (17 maximum) Prerequisite: Minimum IAQ Performance Environmental tobacco smoke control Indoor Chemical and Pollutant Source Controllability of Lighting for 90% of occupants (assume in offices) Thermal Comfort for Design (ASHRAE 55) Survey of Thermal Comfort Daylight and view of 75% of spaces Daylight and Views 90% occupied spaces

18 Lighting Controls Variable Load Shedding Daylight Harvesting Occupancy Controller Task Tuning Smart Time Scheduling Wall Switch Controller Personal Controller Personal Computer Interface with Lighting Controller

19 LEED Points Achieved Innovation - 2 points achieved (5 Possible) No Prerequisite LEED person on team Client has elected to change company policy on air changes and setbacks for air changes in a non occupied mode. This change would involve QA/QC and would mark an industry change in the Pharmaceutical Industry.

20 LEED Summary Possible Points Area Achieved Maximum Sustainable Sites 7 14 Water Efficiency 3 5 Energy & Atmosphere 4 17 Materials & Resources 4 13 Indoor Environmental Quality Innovation & Design 2 5 Process TOTAL POINTS (Range would be certified to silver( 33 ))

21 Additional Costs ISPE Cost Project Construction Cost $40,000,000 Additional Design Cost for LEED $100,000 Additional capital costs for LEED $265,000 Total cost for LEED $365,000 % of total construction cost Less than 1%

22 Project Impact (Costs) Increased Design Fees Increased Owner Participation Increased General Conditions Increased Construction Costs

23 Project Impact Benefits Greater Employee Productivity Natural Light Indoor Air Quality= increased productivity? Operational Savings Maintenance (better documentation) Best Practices

24 Issues for the USGBC U.S. Green Building Council Heat Recovery/Energy efficiency for manufacturing processes. Is Process water exempt from water requirements? Photovoltaic $$$ vs. roof area conflict for high loads. Setbacks on clean rooms during unoccupied times. Lighting Control for Manufacturing space. Definition of occupants for manufacturing space. Wind Wake analysis- why not a LEED point? Daylight for manufacturing- how to define? Building Efficiency- net/gross building volume and orientation 10.5% Energy reduction is difficult- Delete Process loads? Why increase ventilation when it increases energy?