Design for Efficiency Scheme

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Design for Efficiency Scheme

Ang Chye Peng, Engineer Resource Conservation
Department
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Objective

• To encourage investors in new facilities in
  Singapore to integrate energy and resource
  efficiency improvements into manufacturing
  development plans early in the design stage
• This scheme is targeted at large consumers of
  energy

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Design Workshop

• Energy efficient facilities are most effectively
  developed through design workshops (also known as
  design charrettes)
• Design workshop
• An intensive, highly integrative and
  multi-disciplinary 2-3 day session that brings
  together multiple internal experts (home team)
  and external experts (visiting team) at the
  design stage

VISITING TEAM
Expert facilitation and process support Technical expertise
HOME TEAM HOME TEAM
Building owner Building users Building operator Project Manager Facility directors Facility operators Architect Interior designer Electrical engineer Mechanical engineer Contractors Etc.
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Design Workshop

• By fostering cross-disciplinary interaction,
  design workshops encourage the exchange of ideas
  and information, allowing truly integrated design
  solutions to take form and generating solutions
  that would otherwise remain obscured by
  conventional thinking.
• Requires 3-4 months preparation for maximum
  success
• Most effective very early in design phase

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Design Workshop Outcomes

• Opportunities in
• Resource efficiency reduced demand (energy,
  water, gases)
• Waste reduction and reuse
• Cost-effective supply (energy, water, etc.)
• Conceptual design for high-efficiency plant and
  systems
• Preliminary estimates of net cost and
  payback/return

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Design Workshop Success Stories

• In 2008, a design workshop was conducted by Rocky
  Mountain Institute (RMI) to think through EDSs
  plan for a new data center and identify
  opportunities for breakthrough energy efficiency.

• The design workshop identified advanced design
  measures that will substantially reduce energy
  use and likely lead to increased revenue.
• The capital cost savings are estimated at
  US28.2mil and the annual energy savings are
  US1.8mil.

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Design Workshop Success Stories

• In Texas, Texas Instruments (TI) broke ground on
  a state-of-the-art, 100,000 m2 chip fab (with
  20,000 m2 of clean room), designed with ideas
  generated at a design workshop conducted by Rocky
  Mountain Institute (RMI).
• The new facility cut energy use by 20 and water
  use by 35, compared with TI's previous wafer
  fab.
• At least US750,000 in operating costs in first
  year, more than US3mil per year at full build.
• Savings come about half each from better tools
  and their direct support equipment and from
  smaller, more efficient utilities and building
  systems.

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Form of Assistance

• Grant quantum
• 80 of the qualifying costs or S600,000,
  whichever is lower
• Qualifying costs
• Qualifying costs would include the design
  workshop fees
• Consultancy fees, comprising manpower and
  overheads
• Transportation and accommodation for consultants
• Venue and other logistical costs for workshop

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Eligibility Criteria

• Company
• Owner or operator of new industrial facility in
  Singapore
• Consultants
• Experienced external consultants with good track
  record in carrying out design workshops of a
  comparable scale and scope
• Consultants should be external experts
  providing facilitation and technical expertise to
  the design workshop. They should not be design
  consultants directly involved in design
  development.

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Process
Company submits application with copy of proposed
contract with consultant
Approval granted
Within 4 months
Company signs contract with consultant
40 reimbursed
Within 6 months
Consultant conducts design workshop
Within 14 months
Within 2 months
Company submits design workshop report
40 reimbursed
Company submits assessment report
20 reimbursed
END
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More Information

• Application form and more information are
  available at http//www.e2singapore.gov.sg/design
  -for-efficiency.html

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Thank you
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Design Workshop Results EDS

• Key design recommendations included
• Replacing entry level servers with
  best-in-energy-class equipment
• Consolidating entry level servers by removing
  unused equipment, rationalizing applications and
  virtualizing
• Reducing electrical system uninterruptible power
  supply (UPS) redundancy
• Replacing static UPS system with a rotary hybrid
  system
• Eliminating chillers by using an outside air
  economizer system with backup direct evaporative
  cooling
• Replacing the raised floor with a mezzanine deck
  as the supporting structure for the IT equipment,
  providing flexibility increased floor space and
  potential for a future liquid cooling system
• Using supply and return air plenums instead of
  ducts
• Pursuing a BREEAM-certified green building
• Using a 10-15,000 SF pod system to populate the
  data center a fully-utilized pod at a time
• Implementing hardware and software for measuring,
  monitoring, and displaying energy use,
  environmental variables, and server performance
• Developing pricing systems based on client value,
  and financially rewarding both EDS and the client
  for efficiency and elimination of waste
• Creating an EDS-internal incentive structure
  (including metrics, measurement and incentives)
  to drive positive economic change

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Design Workshop Results Texas Instruments

• Design concepts include
• Internally cooled tools with heat exchangers
  designed to lose less pressure and temperature -
  3,000-gallon-per-minute reduction in the size of
  the central process cooling water system.
• Nearly doubled-efficiency vacuum pumps, cut to
  idle speed when waiting for wafers, saved 300
  tons of chiller capacity (vacuum-pump vendors
  have to design and supply new pumps) - saved a
  fifth of internally cooled tools' cooling-water
  flow.
• Split chiller plant that cools water to two
  different temperatures for different purposes
  (further innovation might even eliminate one of
  the two sections in the next fab).
• Highly efficient fan filter units for air
  recirculation prechilling incoming hot air with
  outgoing cool air big pipes and small pumps to
  cut friction and capital cost natural
  daylighting and highly efficient lighting
  fixtures in the office area solar water heating
  a reflective roof and extensive water recycling
  and reuse
• Recovering heat and using high-pressure water
  spray rather than steam for humidification,
  reduced six boilers to just one plus a backup --
  both of which will be off most of the year --
  cutting emissions of nitrogen oxides by 60