living in harmony with nature challenges in operation & maintenance of green buildings dec 2012...
TRANSCRIPT
Living in harmony with Nature
Challenges in Operation & Maintenance of Green Buildings
Dec 2012
ISHRAE : Acre Serve
Tejwant Navalkar
Living in harmony with Nature
AGENDA
• Green Buildings – Concepts
• Review of Current Maintenance Practices
• Need for “Green Maintenance”
• Monitoring for effective Control
• Participation of Maintenance at Design Stage
• Conclusion
Living in harmony with Nature
Living in harmony with Nature
Green Buildings are :
• Resource efficient buildings
• Very energy efficient,
• Utilize construction materials wisely; including recycled, renewable, and reused resources to the maximum extent practical
• Are Designed, constructed and commissioned to ensure they are healthy for their occupants,
• Have lower operating and owning costs,
• Respect and maintain ecological balance
• Are good for the earth planet
What are Green Buildings
Living in harmony with Nature
• Sustainability
Meeting the needs of people today without destroying the resources that will be needed by future generation
• Energy EfficiencyUsing Equipment which require lowest input energy to deliver
their outputs
• Efficient Water ManagementImplementing effective control on water usage, minimising
wastage of water, recycling waste water and judicious selection of landscape plants
• Recycling and reuse of Materials
• Indoor Environmental QualityMonitoring and controlling the quality of air circulated through
air- conditioned spaces, providing lighting levels for minimal eye strain and ensuring noise levels are within comfort zone
Factors contributing to Green Buildings
Living in harmony with Nature
• Environmental Concern
Responsible disposal of waste, recycling of waste and use of non-ozone depleting materials
• Infrastrucutre Planning Providing good Infrastructure in terms of clean, stable
power, good regular supply of potable water and efficient waste disposal, combined with easy access to public transportation.
• Use of Renewable EnergyEnsures virtually Zero Global Warming and provides self
reliance from external agencies in meeting its energy needs
• Staff and User TrainingTraining individual users, owners, staff and inhabitants
of buildings in avoidance of wastage, recycling, correct use of equipment and the importance of effective maintenance in ensuring optimum efficiencies at all times
Factors contributing to Green Buildings
Living in harmony with Nature
Living in harmony with Nature
Some Interesting Photos
Rusted chilled water pipe Broken Insulation chilled water pipeRusted chilled water pipe
Broken Insulation on Valves
Badly dressed cablesCables connected without
lugs Badly laid cables
Living in harmony with Nature
Some Interesting Photos
Badly maintained condenser piping
Badly maintained Cooling Tower
Rusted Chilled water piping
Badly dressed cables Cables dangling in the open
Unarmoured cable laid in water
Living in harmony with Nature
Some Interesting Photos
Badly maintained plumbing pipes
Badly maintained AC outdoor units on terrace
Open Manhole covers
Badly maintained Pumping station
Terrace – Dumping PlaceWater logged terrace
Living in harmony with Nature
• Today a majority of the maintenance is re-active in nature
• Scheduled Maintenance Programs are done on a few equipment based on :
the manufacturers recommendations
judgement of the chief or past tradition
• Log books are maintained for a few equipment where hourly readings of certain parameters are recorded
• Very rarely are these readings analyzed or collated to generate a trend analysis
• No on line measurement of energy or water consumption by energy centres
• No effective equipment replacement plan
Current Maintenance Practices (1/3)
Living in harmony with Nature
• There is no organized Complaint Management System
• Complaints are noted in a register and attended on a best effort basis
• There are no standard time to repair, no history of complaints and no mean time between failure (MTBF) records being generated from the complaints completed
• Due to lack of complaint history, the present stocking of spares is almost entirely based on serendipity; either it is never stocked or it remains a non-moving item for years
• Air-balancing, room temperatures, diffuser/ grille temperatures are very rarely measured
• Water Analysis of the cooling tower make-up water or boiler feed water is rarely done on a planned basis
• Insulation of pipes, ducts is rarely checked and repaired
Current Maintenance Practices (2/3)
Living in harmony with Nature
• No thermography is done on electrical panels to detect any corrosion in joints or any loose connections
• Cables after repairs are not properly dressed
• Light fittings are not cleaned as a part of routine maintenance
• Lux levels in work areas and cabins are never measured
• No effort is taken to identify over designed or under designed equipment
• AHU rooms, Electric meter rooms become dumping yards for all sort of boxes, unwanted material, chairs etc.
Current Maintenance Practices (3/3)
Living in harmony with Nature
Living in harmony with Nature
GREEN Maintenance Practices
• Effort should be taken to shift from Re-active Maintenance to Pro-Active Maintenance and eventually to Predictive Maintenance
• Electric sub-meters, connected to a central energy monitoring system, should be installed at each energy consumption centre
• Daily, Monthly and Annual reports should be generated from these energy consumption readings for analysis
• After analysis, efforts should be taken to identify the ways and means of :
Reducing Maximum demand
Utilising lower night time tariffs and avoiding peak time consumption
• Similarly water sub-meters should be installed at major consumption centres
Living in harmony with Nature
Living in harmony with Nature
0
1000
2000
3000
4000
5000
TIME OF DAY
EN
ER
GY
kW
TOTAL
Base Load
Peak Load
Daily Energy Consumption in a Typical Industry
• Energy Consumption Pattern above depicts the following characteristics during its 24 hour cycle :
A base load of about 40-50% of the peak load
About 3 - 4 peaks during the day
• Peak Loads decides the Maximum Demand and consequently the Power Tariff
Living in harmony with Nature
• Introducing Controls in a running building may be difficult
• However it is possible to introduce instruments to :
Analyze critical Operating System Parameters
Measure Energy Consumption at distributed stages in the process
Automate Start-up/ Shutdown of processes
Generate Alarms/ Reports during exception conditions
Analysing Daily Energy through instruments
Living in harmony with Nature
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5Time of Day
En
erg
y k
W
P-4 P-3 P-2 P-1
Peak Load
Break-up of Daily Energy Consumption
• Based on break-up of daily energy consumption at distributed consumption centres, it is possible to :
Impose Energy Demand Load Limits
Impose Constraints of usage Requirements
Optimize the overall operation
Evenly distribute energy loads to reduce peaks
Take advantage of Time of Day Tariff
Living in harmony with Nature
Effect of Re-Engineering
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5Time of Day
En
erg
y k
W
P-4 P-3 P-2 P-1
Modified Peak Load
Old Peak Load
Living in harmony with Nature
Living in harmony with Nature
Average Power Consumed for a day : Pharmaceutical Company
Energy Measurements – Case Study
Living in harmony with Nature
Energy Measurements – Case Study
Power Consumed by a Compressor for a day : Pharmaceutical Co
Living in harmony with Nature
Energy Measurements – Case Study
Thermography of Electric Panel : Processing Lab
Living in harmony with Nature
Identification of Over/ Under designed Motors
Sr No
Description Rated KW
Max KW Consumed
Avg. KW Consumed
Diff of Rated KW over Max
KW
Diff of Rated KW over Avg
KW 1 ETP Compressor 7.5 HP 5.60 0.38 0.31 14.74 18.06 2 Air Washer No. 2 7.50 1.30 1.24 5.77 6.05 3 AHU-5 Fan 11.00 2.75 2.64 4.00 4.17 4 Extruder Motor Repocessing Plant 30.00 9.85 8.64 3.05 3.47 5 Distillation C. T. Pump 7.50 2.90 2.80 2.59 2.68 6 Air Washer No. 1 15.00 5.91 5.72 2.54 2.62 7 AHU-1, 2, 3 & 4 Fans 18.50 10.10 9.59 1.83 1.93 8 ETP Pump 5 HP 3.70 2.03 1.98 1.82 1.87 9 Solution Cooling Tower Pump 7.50 4.64 4.20 1.62 1.79
10 Autoclave Exhaust Fan 5.50 3.43 3.32 1.60 1.66 11 Grinder Motor Repocessing Plant 11.00 7.25 6.34 1.52 1.74 12 Boiler Blower Fan 22.50 15.26 11.62 1.47 1.94 13 Booster Pump 3.70 2.55 1.54 1.45 2.40 14 Autoclave-1 22.00 16.07 10.59 1.37 2.08 15 Hot Cold Circ. Pumps 3 & 4 7.50 5.48 4.81 1.37 1.56 16 Autoclave-3 9.30 7.01 3.24 1.33 2.87 17 Cooling Tower Pump (25 HP) 15.50 13.15 12.41 1.18 1.25 18 Compressor – No. 1 45.00 38.19 18.70 1.18 2.41 19 Compressor – No. 2 45.00 39.42 38.40 1.14 1.17 20 Boiler Feed Water Pump 15.00 14.32 2.99 1.05 5.02 21 Hot Cold Circ. Pumps 1 & 2 5.50 5.46 5.19 1.01 1.06 22 Chilled Water Pump 9.30 9.28 9.05 1.00 1.03 23 Reverse Osmosis Multistage Pump 11.00 11.00 5.39 1.00 2.04 24 Autoclave-2 9.30 9.61 7.95 0.97 1.17 25 WFI Pump 7.50 10.60 6.65 0.71 1.13 26 Ultra Filtration Pump 3.73 6.41 3.64 0.58 1.02
Living in harmony with Nature
Health Monitoring of Equipment
• Critical health parameters of equipment must be identified and on-line measurements of these parameters provided to give and insight into the health of the equipment
• In some cases, like dirty filter or water flow switches, alarms may be generated if the threshold conditions are crossed
• Threshold conditions can be established for each of the health parameter for an equipment, much like that of a human being
• By continuous measurement of the health parameters, we can move towards predictive maintenance, ensuring against expensive, unplanned and forced shutdowns
• By giving each machine its own customized treatment the life of the equipment is increased and its initial efficiency retained for longer period
Living in harmony with Nature
Winding Temperature Sensors
Vibration Sensors Current Consumption
Rotation Speed
Data Acquisition & Control System
Equipment Monitored
Computer Workstation
EQUIPMENT HEALTH MONITORING SCHEMATIC
Equipment Health Monitoring
Living in harmony with Nature
On-line Complaint / Breakdown Manangement System
• On-line Complaint/ Break-down Management system should be introduced
• This would help in building complaint history for each equipment and provide valuable information regarding mean time between failures, replacement indication and build complaint history
• Complaint History would provide effective means for deciding on spares stocking
• Complaint Management coupled with the Equipment Health Monitoring, provides the right tools for predictive maintenance
• Efficiencies of each equipment can be effectively monitored
Living in harmony with Nature
Other GREEN Maintenance Practices
• Ensure that the Fresh Air Dampers and other Volume control dampers are in working condition
• Ensure that all insulated piping and ducting is proper and no air leakages occur in ducting above the false ceiling
• Use of bio-degradable organic chemicals for anti-scaling and anti-algae formation in cooling tower basins
• Explore avenues for introducing energy efficient light fittings and other equipment
• Introduce Renewable Energy resources wherever feasible especially for 24-hour operating lights
• Educate and train all staff in the importance of avoiding wastage of resources and recycling of material
Living in harmony with Nature
Living in harmony with Nature
Participation at Planning, Design & Execution Stage
• It is very critical to involve the Operations and Maintenance staff at the Design stage, so that Operations related issues are addressed
• It will ensure that equipment are installed with proper access for maintenance
• Instrumentation for central Monitoring and Control is planned and built into the equipment at the design stage
• The Maintenance staff get involved during execution stage so that the entire cabling, ducting and piping route and the technical specifications of equipment are known
• Maintenance staff being associated with vendors during execution stage helps in smooth handover after
commissioning
Living in harmony with Nature
Tejwant Navalkar : +91-9821411436 [email protected]
Contact Details
DFX Systems Pvt LtdEngineering & Renewable Energy Solutions
Your Partner
in
Designing For eXcellence www.dfxsystems.org
Tel: 91-22-2432 4083
Fax: 91-22-2432 5644
Living in harmony with Nature