Design for Efficiency Scheme

1. Design for Efficiency Scheme Ang Chye Peng, Engineer Resource Conservation Department

2. 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

3. 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

4. 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

5. 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

6. Design Workshop Success Stories • In 2008, a design workshop was conducted by Rocky Mountain Institute (RMI) to think through EDS’s 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 US$28.2mil and the annual energy savings are US$1.8mil.

7. 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 US$750,000 in operating costs in first year, more than US$3mil 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.

8. Form of Assistance • Grant quantum • 80% of the qualifying costs or S$600,000, 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

9. 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.

10. 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

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

12. Thank you

13. 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

14. 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%