Optimising your company’s centralised ventilation system
To ensure that the ventilation system is working properly and monitor the financial impact, regular analysis of requirements and technological monitoring are necessary. In the detailed description below, you can find the analysis to be applied in the case of ventilation renewal.
As a first step, we strongly advise you to carry out a detailed analysis of your company’s current ventilation situation and requirements, and to anticipate possible changes in requirements in the future (building project, change of use of certain rooms, etc.)
On the basis of this analysis, the new ventilation system can be sized.
Campus Contern offers 16,000 m2 of office space for rent. There are five buildings in which around 450 people from 34 different companies work. The aim of Campus Contern is to provide innovative coworking spaces in terms of sustainable development and the well-being of their occupants. As a result, they have been awarded the BREEAM Excellent label, the CO2-neutral certificate (the first for any office building in Luxembourg) and CSR certification.
Idea
Optimisation of the building for improved energy efficiency.
Using a smart regulation system may allow to compare consumption on a daily/monthly basis and to optimise the use of equipment in order to reduce costs (and protect natural resources).
Optimising consumption on a building level:
The natural heat provided by sunlight and the heat generated by the computer rooms throughout the building can be used to reduce the use of heating and air-conditioning.
LED lighting has been upgraded with integrated occupancy sensors and smart meters to measure consumption and allow for remote preemptive maintenance.
Design
Smart heat utilisation
During the development phase of the site, Campus Contern introduced a clever technology: they reused the warm air from the southern areas and the IT rooms to heat the northern areas, thereby avoiding excessive use of air conditioning and heating. The plan then was to give occupants some flexibility to adjust the system to their liking, with a margin of +/- 2°C relative to the reference value. And when the windows are opened, the air conditioning or heating automatically switches to standby mode.
In terms of lighting, they introduced LED lights and equipped the common areas and parking spaces with occupancy sensors. The lighting in the outdoor car park, in turn, is controlled by a twilight sensor and smart scheduling.
The advantage of smart meters is that they collect a maximum of useful information for a detailed analysis of energy consumption. It is also possible to carry out efficient remote interventions, detect potential anomalies more quickly, optimise the installation and streamline maintenance.
Implementation
Meticulous planning to minimise any disruption
Each project required meticulous planning, particularly with regard to the sequencing of work and the necessary controls.
The manager was responsible for coordinating the work of the various service providers and communicating with the tenants. Good planning and effective coordination were essential. Where access to private areas was required, it was essential to minimise any disruption, for example when replacing light fittings or installing meters.
Campus Contern planned most of the work over the weekend to minimise interference with working conditions and the confidentiality of everyone’s activities. Nevertheless, there were unforeseen incidents such as the adjustment of light fixtures, the adjustment of time-delays or the detection of malfunctions after the installation of sensors/meters (as it was not possible to perform the final inspection zone by zone over the weekend).
Result
More control means better management
With building intelligence, energy consumption can be made transparent and accurately tracked, which opens up the possibility of adjusting and optimising the parameters of all HVAC technology and luminaires. In addition to energy efficiency, this also ensures optimal comfort for the building’s occupants.
The company Gilles Tooling was founded in 2005 and produces various attachments for the motorcycle industry according to the highest standards. These include chain tensioners, footrest systems, brake and clutch levers and protectors.
In addition to private customers and retailers, the company’s customers include big names such as BMW, Yamaha, KTM, Suzuki and Polaris. The company is based in the Potaschberg industrial estate in the municipality of Grevenmacher and currently employs around 70 people. Their main activities lie in the research and development and manufacturing divisions. The latter is the area in which a large part of the electricity and heat costs originate.
Idea
Eliminating compressed air leaks with the aid of an ultrasonic camera
Due to the ongoing fluctuations in energy prices, manufacturing companies are naturally striving to control these costs as much as possible and to optimise energy savings.
To this end, the company has examined its compressed air supply and concluded that there is considerable potential for energy savings. Compressed air is needed at every machine and at every workstation in production: predominantly for the fully automated milling machinery, but just as well for other processes such as cleaning, degassing or assembly.
The analysis showed that the continuous expansion of the production has led to a very complex compressed air network, which regularly incurs losses through leaks.
Because production operates continuously around the clock, and there is an inherent noise level in the production hall, it is not possible to audibly identify any leaks through hissing noises. Consequently, it became evident that an alternative solution was needed to identify any potential leaks.
Following research, a conclusion was reached that an ultrasonic camera would be the appropriate solution.
Design
Exchange with the House of Sustainability
The company got its first information on financial support on guichet.lu. For the acquisition of the device, which amounted to a four-digit sum, they were able to draw on the financial support of the “SME Package – Sustainability” programme. With the help of the House of Sustainability, they were able to prepare their application file in a very objective and uncomplicated manner. This included soliciting offers, completing the application and obtaining the approval message from the House of Sustainability. The contract could then be issued.
Implementation
Employing an ultrasound camera
The device is easy to operate and allows the compressed air network to be inspected while the machines remain running. The camera shows an ultrasound image of the plant, on which one can see the location and extent of the leakage. Based on the resulting data, it is then possible to assess how quickly a response is needed.
The ultrasonic camera is used for both suspected leaks as well as regular maintenance of the compressed air supply.
Results
Savings on electricity bills
According to the company’s internal calculations, the cost of one cubic metre (1 m3 ) of compressed air is about 3.38 cents. At a network pressure of 8 bar, approximately 4.5 m3/h (15.21 cents) would leak from a breach of 1 mm in diameter.
Based on the company’s experience and on the leaks that have already been detected and repaired, this results in an estimated loss of 100 m3/h. This leads to losses of 3.38 €/h and a total of around 30,000 € over an entire year.
Caméra à ultrasons Gilles Tooling S.à.r.l.Gilles Tooling S.à.r.l.
The CERATIZIT Group is a leading developer and manufacturer of hard material solutions for cutting tools and wear protection.
At its headquarters in Mamer, the company develops and manufactures highly specialised cutting tools, cutting inserts, hard material rods and wear parts.
The engineering group employs 7,000 people, including 1,200 in Luxembourg.
Idea
Addition of a Solar carport
As part of the company’s sustainability strategy, a solar carport was constructed. The project provides a combined solution for generating photovoltaic energy and providing an electric charging infrastructure for company and private vehicles.
An added benefit of the project’s design is the added protection for cars in the outdoor parking lot.
Design
Deploying a green strategy with the help of Enerdeal
Ceratizit commissioned Enerdeal to install, operate and finance the carport as part of the group’s ambitious green strategy.
The structural design is based on rammed metal pile foundations (up to 6 m deep). The panels face south.
After 15 years of operation, the ownership of the system will be transferred to Ceratizit, providing for at least an additional 15 years of solar production.
As for financial aid, the company participated in a call for tenders to obtain a “market premium” (guaranteed minimum price) for the reinjection of electricity into the grid for 15 years. In terms of project regulations, a building permit has been obtained from the local authority.
Implementation
12 months to project completion
The total duration of the project amounted to around 12 months, with the actual construction phase taking no more than 4 months. The work was divided between the construction of the carport, with the integration of the photovoltaic system by Enerdeal, and the installation of the charging stations by Elco. The operation of the plant will be guaranteed by a financing subsidiary between Enerdeal and Sudstroum, named “Sudsolar Energy Invest2”. The project entails an investment of 1.8 million euros.
Results
Electricity injected directly into the grid
The project to install an electricity generation system in combination with a charging infrastructure for electric vehicles can be summarized by the following key figures:
100% electric energy fed back into the grid
Approx. 442 parking spaces (10% electromobility)
Installed capacity of 1,320 kWp, i.e. 3,520 panels of 375 Wp each
Parking space of 6,200 m2 (covered)
Annual production of 1,400 MWh in 2022, i.e. around 638 tonnes of CO2 saved per year
charging points for electric vehicles
2 types of charging station: 11 kW for semi-fast charging and 60 kW for fast charging.
The carpentry workshop Arnold Becker S.à.r.l. and its 22 employees are located on the Echternach industrial park. The company designs, produces and installs windows, doors, staircases, furniture and kitchens of its own manufacture.
The carpentry works constantly to reduce its carbon footprint and, from an economic standpoint, to cut significant energy costs so that it can continue to produce competitively.
Idea
Lighting replacement and optimisation
The management of the carpentry business decided to ‘relamp’ its entire facility, including the production halls, showroom and administrative area. This meant replacing all of the lighting, which consisted mainly of fluorescent tubes, with LED sources, without replacing the lighting units themselves.
Design
Exchange with the Chambre des Métiers
“We found out about the SME-Package Sustainability financial assistance programme through the Chambre des Métiers newsletters. After discussions with the Chambre des Métiers, the grant application was drawn up in consultation with us”, explains Simon Becker of Arnold Becker S.à.r.l.. The receipt of the lump-sum subsidy was acknowledged fairly quickly, and the carpentry firm was then able to place the order for the installation.
Implementation
Upgrading the lighting to LED bulbs
The carpentry workshop used its own lifting platform to relamp the lighting, which allowed the conversion to LED lamps to be completed within two weeks and without any notable difficulties. According to Mr Becker, the entire project, from the idea to the execution, took about three months.
Results
Savings on electricity bills
The savings are not yet reflected in the electricity bill, but the company commissioned has estimated annual savings of around 27,000 kWh. In retrospect, the implementation of such a measure is highly recommended, as it is inexpensive and, coupled with the reported financial support, has a short payback period. Other advantages of relamping include the longer lifespan of the light source, which reduces the replacement rate and associated costs. Secondly, unlike fluorescent tubes, LED technology ensures that the lighting intensity is not reduced in production halls at lower temperatures, thereby improving working conditions.
Schreinerei BeckerShowroomShowroomHalles de production
Energy savings: lighting, a key element in energy consumption in the workplace
Lighting accounts for around 10% of electricity consumption in buildings. The potential savings are quite varied and depend heavily on the condition and management of the lighting system. In order to unlock the full potential, this measure proposes a range of optimisation measures, from simple practical initiatives to a complete overhaul of the lighting system.
The heating installation: an important leverage point in the energy transition
The heat production unit is a major leverage point for a successful energy transition. As its primary purpose is to supply heat for comfort and operational needs, the heating system must be scaled to provide the temperature levels and necessary quantities to keep the business running. Nowadays, there are heat production systems that are adapted to each temperature level are flexible in terms of power and are environmentally friendly.
Ensuring efficient heating system performance in the workplace
The production of heat for premises and production processes represents a major cost factor. To reduce heating costs, This is why it is essential to ensure that the heating system operates correctly and is as economical as possible. This also includes all peripheral installations, heat production and distribution.
Control operating costs related to compressed air systems in the company
Compressed air is an energy carrier that is frequently used in many sectors, particularly in the use of production machinery and specific pneumatic tools. Despite its abundant use, it is a complex medium to control, resulting in high operating costs. In an unmonitored installation, losses during heat generation and distribution due to leaks can be up to 90 %. Compressed air costs can be contained by regularly analysing energy requirements and through technological monitoring. This measure is required for every new compressed air system.
Compressed air: an energy carrier that needs optimising in numerous sectors
Compressed air is an energy carrier that is frequently used in many sectors, particularly in the use of production machinery and specific pneumatic tools. Despite its abundant use, it is a complex medium to control, resulting in high operating costs. In an unmonitored installation, as much as 90% of the losses in heat generation and distribution can be linked to leaks. Compressed air costs can be contained by regularly analysing energy requirements and through technological monitoring. This applies to all new compressed air system.
