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TRANSCRIPT
Facilities Management
Bobby Rauf, ©
9/24/2010 Facilities Mgt. Seminar; © B. Rauf 1
Table of Contents
• Maintenance Engineering and Management
• Electrical and Controls
• Plant Project Engineering and Management
• Safety in Industrial Environment
• HVAC
• Energy Conservation and Management
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Maintenance Engineering and Management
Bobby Rauf ©
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Topics
• Maintenance Statistics
• Recommended Best Practices for Maintenance Organizations
• Examples of Computer Based Work Order Systems
• Maintenance Personnel Leadership and Management Skills
• Maintenance’s Role In Plant Spare Parts Inventory.
• Preventive Maintenance
• Predictive Maintenance
• Mechanical, Electrical and Controls Best Practices, within the Maintenance Organization
• Maintenance Training and Support
• Motor Repair vs. Replace Decisions
• Cost Reduction, Repair vs. Replace Decisions
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Maintenance Statistics:
• Approximately, 30% of Manufacturing and Process Plants have Maintenance Planners and some sort of Work Order System.
• Less than 15% of the Maintenance Planners are utilized effectively and efficiently.
• A significant majority of Maintenance Organizations view their Work Order Systems as inadequate and inefficient.
• Most Maintenance Organizations lack specific Missions Statements, Goals, and Measurable Targets.
• Most Maintenance Organizations lack established Performance Monitoring, Performance Analysis and Feedback Systems that are geared toward enhancing their Effectiveness and Continuous Improvement.
• A vast number of Manufacturing Facilities and Process Plants don’t pursue Failure Analysis of Systems or Significant Components.
• A significant portion of Maintenance Organizations do not perform Predictive Maintenance and consider it a Luxury.
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Recommended Best Practices for Maint. Organizations:
• Perform Maintenance Cost Analysis:– Rank Maintenance Categories by Cost
• List Top Five to Ten Areas of Cost• Does the 80 – 20 Rule Apply?
– For instance, is 80% of the Maintenance Cost associated with a few Maintenance Areas, while 20% of the cost might pertain to a multitude of small cost categories?
• Have maintenance craft and planners provide quotes on planned work and compare with outside sources. Cost or price competition yields higher labor efficiency and lower cost.
• Maintenance Efficiency is directly proportional to Maintenance Planning.– Minimize Unplanned Maintenance Work and Maximize Planned
Maintenance Work• All maintenance work must be covered by Maintenance Work Order System
– Minimize Break of Schedules or Scheduled Work Orders• In Successful and Effective Maintenance Organizations, most of the Work
Orders originate from Preventive Maintenance Inspections and Predictive Maintenance Programs.
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Recommended Best Practices for Maintenance Organizations, Continued:
• Maximize Facilities or Manufacturing Equipment O.E., Operating Efficiency:– Operating Efficiency is defined in terms of the following formula:
• O.E. (%) = (Equipment Up Time / Total Expected Run Time of Equipment) x 100
• Maximize or Optimize Equipment Life through some of the following means, as applicable:– Correct application and optimized operation of equipment.
– Strict discipline in scheduling and implementing periodic preventive and predictive maintenance.
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Examples of Computer Based Work Order Systems:
• Maximo, by MRO Software Co.– Work Order Entry
• Work Plan• Recommends Parts, Equipment and Craft
– Work Order Tracking• Work Order Originator and Other Pertinent History• Schedule• Maintenance Person Assigned to the Work Order• Cost
– Spare Parts Inventory– Illustrated Parts Catalog
• Equipment Diagrams/Drawings• Bill of Materials
– Preventive and Predictive Maintenance Schedules– Purchasing– Pertinent Safety Information and Regulations.– Key Performance Indicators.
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Examples of Computer Based Work Order Systems:
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Examples of Computer Based Work Order Systems:
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Examples of Computer Based Work Order Systems, Contd:
• Express Maintenance offers many powerful features and data entry fields you simply will not find in other maintenance programs. Here are just a few examples:
• Save photos and images of equipment, parts and employees• Built-in Report Designer lets you design your own reports• Create unlimited sites / locations for equipment and parts• Create unlimited categories of equipment, parts and services• Create unlimited services, intervals, periods and estimates• Include general and safety notes with every service• Create and print barcodes with parts and equipment• Data entry fields for devices and valves including types, pressures, sizes, connectors, outlet
/ inlet size, volts, amps, etc.• Complete vehicle and equipment fields including serial numbers for engine, transmission,
chassis, and body• Complete warranty and lease data fields• Units screen includes fields for everything you need to track plus user definable fields and
selection lists• Units screen includes tab for tracking & graphing downtime.• Quickly review maintenance that is due and automatically generate work orders.• Track work orders performed by your staff as well as outside sources• Track part and equipment suppliers and costs• Issue purchase orders and track receiving of parts• User setup screen allows administrator to determine to which screens each user will have
access and what level of access
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Examples of Computer Based Work Order Systems, Contd.:
• Express Maintenance will save your company plenty of money in the short and long run. Now, you will be able to accurately and effectively track scheduled and un-scheduled maintenance on all sorts of equipment and parts. Here are a few of the benefits you'll see from Express Maintenance immediately:
• Protect inventory and reduce shrinkage of parts• Maintain equipment more efficiently and effectively• Generate work orders and manage personnel time more effectively• Track actual and estimated expenses of various services• Track safety and other notes on any service• Track scheduled and non-scheduled services• Monitor supplier pricing and know who is the best source• Track equipment warranty information• Know what services have been performed on equipment with unlimited service
history• Save time by having services automatically scheduled for you and know when
they should be performed next• Save time with instant reports and information always at your fingertips
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Examples of Computer Based Work Order Systems:
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Examples of Computer Based Work Order Systems:General Features
• Better support for multiple database or locations setups.
• Get email support from within the application's main menu.
• Automatic Email of work orders to people responsible for their completion. (Learn More)
• User defined fields added to Equipment, Mechanics, Parts and Contacts modules.
• Attach external files and documents to Work Orders, Inventory Items and Equipment (3.2)**
• Barcode labeling added to Equipment and Parts and Inventory modules.
• New Database backup and repair utilities.
• New Budget support for Purchasing and Work Orders (3.2)
• Support for the new optional Work Orders Request module.
• Join tables to custom reports in the Reports and Graphics module. (3.2)
• New Predictive Maintenance Worksheet report in the Issues module. (3.2)
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Maintenance Personnel Leadership and Management Skills:
• Goals Setting Guidelines for Front Line Supervision and Management:– S.M.A.R.T Goals
• “ S” stands for SPECIFIC
• “M” stands for MEASURABLE. “You can’t control what you can’t measure.
• “A” stands for ATTAINABLE.
• “R” stands for REASONABLE.
• “T” stands for “Time” specific.
• Zero Tolerance of Workplace Harassment
• Interpersonal Skills and Understanding Human Behavior– Maslow’s Hierarchy (See Next Slide)
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Maintenance Personnel Leadership and Management Skills:
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Maslow's Hierarchy of Needs
Abraham Maslow is known for establishing the theory of a hierarchy of needs, writing that human beings are motivated by unsatisfied needs, and that certain lower needs need to be satisfied before higher needs can be satisfied. Maslow studied exemplary people such as Albert Einstein, Jane Adams, Eleanor Roosevelt, and Frederick Douglas rather than mentally ill or neurotic people.
Maintenance’s Role In Plant Spare Parts Inventory:
• Maintenance Department must participate in and approve addition of spare parts to stores inventory. Some of the reasons for this approach are as follows:– Avoidance of spare part duplication when parts are common
between various types of plant equipment.
– Proper control of spare parts that repairable or serviceable
• Maintenance must play an active role in Periodic Inventory of Spare Parts
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Preventive Maintenance:
• Reasons for Preventive Maintenance:– To prevent unanticipated equipment breakdowns.Sudden,
unanticipated equipment or structure failure can result in the following:
• Higher Repair Costs• Longer Down Times and Lost Production• Safety Hazards• Possible Cascaded Failures of Upstream and Downstream
Equipment in Multi-Component Systems– To maintain efficiency and productivity of equipment– To prorate and spread maintenance cost over time. This provides
maintenance organization greater control over the facility’s maintenance budget by preventing unexpected surges in negative variances against the budget.
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Preventive Maintenance, Contd:
• Examples of Preventive Maintenance:1. Periodic Lubrication of Equipment:
– Replenish or change oil and grease – Test the replaced oil or grease, if recommended by equipment
manufacturer. Tests performed on lubricants removed from large gear boxes, transmissions, bearings, compressors, engines, cranes, robots and other industrial equipment can diagnose and predict eminent failures.
2. Infrared Thermography – Infrared scan of Electrical Switchgear, Substation and Motor
Control Centers. Look for “hot-spots” and loose connections.– Infrared scan of steam traps.– Infrared scan of overheating motors, bearings and other
mechanical equipment.– Infrared scan of roofs to detect roof leaks.
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Preventive Maintenance, Contd:
Infra Red Thermography
– Cold transformer fins indicative of LOW oil level
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Preventive Maintenance, Contd:
• Examples of Preventive Maintenance, Contd:3. Compressed Air Leak Detection Using Sound Detection Systems:
– Compressed air leaks drop the pressure in compressed air headers and can cascade into malfunction of pressure sensitive equipment such as raw material or batch transport systems, air actuators, valves etc.
– Compressed air leaks are expensive. A 1/8” diameter air leak, at 100 psi, can cost more than $2,000 per year.
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Predictive Maintenance:
• Reasons for Predictive Maintenance:– To prevent equipment failures through early diagnosis, and
prediction of eminent problems. Such predictions can then be followed by planned shut down and repair.
– Lack of Predictive Maintenance Program can result in the following:
• Higher Repair Costs due to Sudden Catastrophic Failures. Some Catastrophic Failures Require Total Replacement of Equipment.
• Longer Down Times and Lost Production• Safety Hazards; e.g. fire and explosion hazard with undetected
loose electrical connections.• Possible Cascaded Failures of Upstream and Downstream
Equipment in Multi-Component Systems; e.g. catastrophic bushing meltdown due to loss of process cooling water.
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Predictive Maintenance, Contd.:
• Examples of Predictive Maintenance:1. Mechanalysis: The concept of relating the level of vibration and
noise, emitted by a machine, to the machine’s condition or performance is called mechanalysis.
– Vibration and noise are measured, recorded, charted and analyzed on critical mechanical equipment, where circular or linear motion is involved.
– All machines vibrate to a certain extent and generate a certain amount of noise.
– The normal noise and vibration constitute a fingerprint of sorts for a particular machine, under normal load.
– The vibration and noise caused by many factors. Some of the factors are listed below: – Unbalance or Misalignment
– Worn Gears or Defective Bearings
– Looseness
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Predictive Maintenance, Contd.:• Examples of Predictive Maintenance:
1. Mechanalysis, General Method or Procedure, Contd:
a) Measure vibration at recommended points. Such as, at or near bearing and at specific points along the drive train
b) Vibration is measured and recorded in the following terms: Displacement or amplitude, in mils Vibration frequency, in CPM Vibration velocity, at peaks, in inches or mm per second Phase difference, in degrees, with respect to a fixed point or
another vibrating part.
c) Record the measured vibration, periodically.
d) Compare the data with established standards to assign a level of severity, or identify the type of problem (i .e. Unbalance, Looseness, Bad Gear or Bad Bearing) by examining the frequency of vibration.
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Predictive Maintenance, Contd.:• Examples of Predictive Maintenance:
1. Mechanalysis, General Method or Procedure, Contd:
e) The periodic measurements of vibration are plotted, graphically, as a function of time or dates.
f) The graph plotted under item “e” depicts the trend of the vibration data. The objective is to look for: Any instantaneous peaks Gradual or sustained increase in vibration amplitude Correlate significant changes in the vibration data to chronological
events through the time or date axis of the chart.
g) Measure, record/chart the noise level, in db’s, using a sound level meter, at recommended points around the equipment.The objective is to look for: Any instantaneous surge in the measured noise level Gradual or sustained increase in the noise level Correlate significant changes in the noise data to chronological events
through the time or date axis of the chart.
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Predictive Maintenance, Contd.:
• Examples of Predictive Maintenance:
– Components of a Typical Mechanalysis System:– Vibration detecting wand
– Microphone
– Monitor & Recorder
– Amplitude meter displays overall vibration level of machine in mils, in/sec, g's and g's se.
– Hard copy printout of vibration spectrum includes correct engineering units, filter bandwidth setting, amplitude and frequency scale values.
– Accelerometer is a rugged, high performance transducer which measures vibration, velocity, acceleration and "spike energy.”
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Predictive Maintenance, Mechanalysis, Contd:
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Predictive Maintenance, Mechanalysis, Contd:
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Mechanical, Electrical and Controls Best Practices, within the Maintenance Organization:
• Break the age old paradigms that Instrument and Control Technicians must be groomed from within the plant’s existing personnel pool:– New technicians, with recent technical training and accreditation, frequently
offer greater service value, at lower wage expense.– New technicians, with recent technical training, bring fresh perspectives and
stimulate reexamining of traditional logic. • Assign a Senior Technician, Maintenance Supervisor or Maintenance Engineer the
responsibility to keep Control and Monitoring Software/Firmware current:– Too often software or firmware upgrade of control PLC’s (Programmable Logic
Controllers) is ignored until the equipment malfunctions or is modified.– Practice strict discipline in securing latest versions of controls and monitoring
programs, at multiple locations.• Maintain a secure documentation and program library, with authorized access
only.• In order to ascertain acquisition of complete documentation, on new projects,
Maintenance must be on the Engineering Project Completion Approval List.
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Mechanical, Electrical and Controls Best Practices, within the Maintenance Organization:
• Install CMMS, Computerized Maintenance Management Systems to simplify scheduling of Preventive Maintenance.
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Maintenance Training and Support:
• Skills and Performance of Maintenance Technicians and Engineers, to a great extent, depend on training. Successful training of key technicians and engineers depends on some of the following factors:– Adequate availability and allocation of funds– Quality and effectiveness of the Training Program and Trainers– Maintenance Management’s Commitment to training– Selection of qualified and motivated technicians and engineers for
training:• On complex, specialized and critical equipment select only those technicians
and maintenance engineers for training who are expected to stay in their current assignments on longer term basis.
– Three (3) veteran technicians were trained through week long courses in robotics, vision system and Wonderware at a North Carolina Manufacturing facility, for a total cost of, approximately, $40,000. Six months later these technicians were a different assignment leaving no skilled maintenance coverage for the robot based automation system. Maintenance of this complex robot based system was contracted out to an external source.
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Maintenance Training and Support, Continued:
• Funds for Maintenance Training:– Allocate funds for training purposes in the annual maintenance budget.– Engineering Projects, pertaining to new technologies, systems or equipment,
must be required to include appropriate amount of funds for mechanical, controls and electrical training
• Engineer, responsible for the engineering and installation of the system, must be required to support the plant for a definite period of time after commissioning of the system
• Evaluate the economics of outsourcing the maintenance function under the following situations:– Facilities with a limited maintenance staff– Prototype or pilot high-tech projects. For instance, a pilot or prototype
systems based on industrial robots, sophisticated vision systems, complex computer based HMI, Human Machine Interface Systems, etc.
– When “loaded” labor rates for in-house maintenance craft exceed the contract rates, significantly.
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Motor Repair vs. Replace Decisions:Ten Questions to Answer Before You Call the Motor Service
Center
1. What is the basic nameplate information? (Include manufacturer, horsepower, speed, voltage, phase, enclosure, catalog, part and/or model number, frame size, and serial number.)
2. What does the motor operate? (A fan, blower, conveyor belt, pump?)3. How does the motor drive the load? (Does it have a direct drive, or is it
belted?)4. Is there auxiliary equipment attached? (A clutch, gearbox, or brake?)5. Why do you think the motor needs repair? (Does it smoke, not run, or
need preventive maintenance?)6. What is the motor’s past repair history? (Is it a “problem motor”?)7. How is the motor started? (Across the line, soft start, adjustable speed
drive, part winding start, wye start, or delta run?)8. What is the operating environment? (Indoors, outdoors, subject to
hazardous fumes or dusts, or water spray?)9. When do you need the motor back? Will you authorize overtime work if
necessary?10. Is the motor still under manufacturer’s warranty?11. Is this an EPACT motor? EPACT stands for Energy Policy Act.
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Flow Chart, Motor Repair vs. Replace Decisions :
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www.easa.comwww.oit.doe.gov/bestpractices/motors
Cost Reduction, Repair vs. Replace Decisions:
Repair vs. Replace decisions involve comparison of the life cycle cost of equipment under two mutually exclusive scenarios:
a) Life Cycle Cost of the piece of equipment in question if it is repaired, vs.
b) Life Cycle Cost if the equipment is replaced.
Life Cycle Cost:Total cost of owning and operating a piece of equipment over its
expected life. This cost would consist of the following:– Initial cost or investment – Total preventive, predictive and other typical maintenance cost over
the life span of the equipment– Fuel, electricity or other energy cost over the life of the equipment.
This would take into account the efficiency of equipment.– Opportunity cost or lost production if the equipment malfunctions.
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Cost Based Motor Repair vs. Replace Decisions:
Sample Problem,
A 100 HP, 480 VAC, 3-Phase blower motor has experienced a ground fault due to winding failure. This motor has been repaired/rewound twice before. The motor has lost 5% of its efficiency during each of the past two (2) rewinds,due to core losses. The maximum actual load on the motor is 90 HP.
- A typical rewind or repair service, for a 100 HP motor is $1,600. - A new premium efficiency motor cost, approximately, $3,400. - Electricity cost at this facility averages $0.05/KWH. - Assume initial efficiency of 96% and a power factor of 0.9.
a) What is the cost of owning, maintaining and operating this motor over a period of 10 years?
– Assume that the motor experiences a ground fault at the 5th year, 8th year and the 10th year.
– Assume 24-7 operation and an average efficiency of 95% over 10 years. Assume that the electricity cost stays constant over 10 Years.
– Assume Lost Production Cost and Maintenance Labor Cost of $ 3,000 per Failure.
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Cost Based Motor Repair vs. Replace Decisions:
Original Efficiency of the Motor is = 96%Motor Efficiency after 1st Rewind = 96% x (1 - .05) = 91.2%Motor Efficiency after 2nd Rewind = 91.2% x (1 - .05) = 86.64%Motor Efficiency after 3rd Rewind = 86.64 HP x (1 - .05) = 82.31%Energy Cost, 1st Five (5) Years
= 100 HP x 0.746 KW/HP x 24H x 365D/Y x 5Y / 0.96 x $0.05/KWH = $ 170,181 Line Current = 104 AmpsAnnual Energy Cost = $ 34,036
Energy Cost, After 1st Rewind, for Three (3) Years= 100 HP x 0.746 KW/HP x 24H x 365D/Y x 3Y / 0.912 x $0.05/KWH = $ 107,483 Line Current = 109 AmpsAnnual Energy Cost = $ 35,828
Energy Cost, After 2nd Rewind, for Two (2) Years= 100 HP x 0.746 KW/HP x 24H x 365D/Y x 2Y / 0.8664 x $0.05/KWH = $ 75,427 Line Current = 115, An 11% Rise in Line CurrentAnnual Energy Cost = $ 37,713
NOTE: After the second rewind, the motor Line Current has risen by 11%.QUESTION: After two (2) Rewinds, is the operating level of Line Current
approaching the Design Limit of the Conductors and the Circuit Breakers?
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Life Cycle Cost of Owning and Operating a 100 HP Motor
Life Cycle Cost Comparison Without Time Value of Money Consideration:
Scenario (1):Rewind Twice, then Replace at 3rd Failure:=( $170,181+$107,483+$75,427)
+($1,600+$1,600+$3,400)+(3)x($3,000) = $ 368,691
Scenario (2):Replace upon 1st Failure:=( $34,036 x 10) + ($3,400+$3,400) + (2)x(3000) = $ 353,163
Replacement Option Life Cycle Cost is Favorable By:$15,528
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Electrical Power & Controls
Bobby Rauf ©
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Topics
• Essential Fundamentals Of Electricity in Industrial and Commercial Environment
• Standards
• Power Distribution Systems
• Pilot Devices
• Variable Frequency Drives
• Smart Motor Controllers (SMCs)
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Fundamentals Of Electricity in Industrial and Commercial Environment
• Voltage• Current• Resistance• Capacitive Reactance• Inductive Reactance• Impedance• Power & Power Factor• Motor Speed Calculation• Motor Line Current Calculation
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Fundamentals Of Electricity in Industrial and Commercial Environment
Voltage :
• Def: Electromotive Force or Electrical Potential Difference Between two Points
• Symbols for Voltage: E, V, VP, VM, VDC, VEff, VRMS,VAC
• Unit for Voltage: Volts
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Fundamentals Of Electricity in Industrial and Commercial Environment
Current :
• Def: Movement of Electrons due to Electromotive Force or Electrical Potential Difference Between two Points is called current.
• Symbols for Current: I, i, I (t), IP, IM, IDC, IEff, IRMS, IAC,
• Unit for Current: Amperes or Amps.– One Amp = One Coulomb / Second
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Fundamentals Of Electricity in Industrial and Commercial Environment
Resistance :• Def: The property of a material (conductor) to
impede or resist flow of current is known as resistance.
• Symbol for Resistance: R – R = ρ . L/A; Where, ρ = Resistivity of the Conductor,
L=Length of the Conductor and A=Area of Cross-Section of the Conductor.
• Unit for Resistance: Ohms or Ωs.– One Ohm = One Volt / One Amp
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Fundamentals Of Electricity in Industrial and Commercial Environment
Capacitive Reactance :
• Definition of Capacitance: Capacity of a Capacitor to Store Electrical Charge.
• Symbol for Capacitance: C
• Symbol for Capacitive Reactance: Xc
• Where, Xc= 1/2πfC
• Unit for Capacitive Reactance: Ohms or Ωs.
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Fundamentals Of Electricity in Industrial and Commercial Environment
Inductive Reactance :
• Definition of Inductance: Capacity of an Inductor to Resist Change in Current Flow.
• Symbol for Inductance: L
• Symbol for Inductive Reactance: Xl
• Where, Xl= 2πfL
• Unit for Inductive Reactance: Ohms or Ωs.
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Fundamentals Of Electricity in Industrial and Commercial Environment
Impedance :• Def: Impedance is the current resisting and
impeding characteristic of load or conductor in an AC Circuit.
• Symbol for Impedance: Z Z = R + jXl - jXc
• Unit for Impedance: Ohms or Ωs.
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Fundamentals Of Electricity in Industrial and Commercial Environment
Power :
• Def: Power is defined as the capacity of a system to perform
work or Rate of work performed by a system.
• Symbols and Types of Power:Papparent = S = Apparent Power (kVA) or Total AC Power
Preal = P = Real Power Component of Apparent Power (kW)
Preactive = Q = Reactive Component Apparent Power (kVAR)
• Papparent = (Preal)2 + (Preactive)2 orS = (P)2 + (Q)2
• Magnitude of Total (3 ∅ ) Power = S= √3 x VL x IL
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Fundamentals Of Electricity in Industrial and Commercial Environment
Power Factor : • Def: Power is defined as the Ratio of Real Power (kW)
to Apparent Power (kVA). It is also defined as the quantity cos(θ - φ).
• PF = P/S or• PF = cos(θ - φ), • where θ is the angle of voltage v = VRMS ∠ θ and • φ is the angle of current i = I RMS ∠ φ• In Inductive Circuits, add Capacitance, or Capacitive
Reactance, Xc, to offset the Inductive Reactance, Xl, and to Increase the PF.
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Fundamentals Of Electricity in Industrial and Commercial Environment
Power Factor Improvement Example:
• Problem:An air compressor station is consuming 2,000 kW at a power factor of 0.8. The
utility company charges a $4.00/kVa per month as demand charge for poor power factor. What would the annual, pre-tax, savings be if capacitors could be installed and power factor improved to 0.9?
• Solution:Apparent Power or Billing kVa at existing Power Factor of 0.8 = 2,000 kW / 0.8 =
2,500 kVaApparent Power or Billing Kva at an improved Power Factor of 0.9 = 2,000 kW /
0.9 = 2,222 kVaDemand Charge Savings = (2500-2222) kVa x $4.00/kVa x 12 Months/Year =
$13,344
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Fundamentals Of Electricity in Industrial and Commercial Environment
Motor Speed Calculation:
• Given:Number of Poles = P = 4
Frequency of AC Power Supply to the Motor, in Hertz = f = 60 Hz
Speed, in RPM = S = ?
– Formula: S x P = 120 x f
» S = (120 x f ) / P
» S = (120 x 60) / 4 = 1800 RPM
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Fundamentals Of Electricity in Industrial and Commercial Environment
Motor Power – Line Current Calculation:
• Motor Nameplate Information:Power rating, in HP (Horse Power) = P = 10 HPVoltage Rating = 480 VACNo. of Phases = 3; also stated as 3 ∅Power Factor = PF = 0.8Efficiency = Eff. = 0.9Magnitude of Line Current = FLA, Full Load Current = I = I = ?Note: 1 HP = 746 Watts = 746 W = 0.746 kW
– Formula: I = Power in Watts / PF / Eff./ (√3 x VL)» I = 10HP x 746 W/HP/0.8/0.9/(√3 x480VAC)
» I = 12.46 Amps
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Standards
• NEMA: National Electrical Manufacturers Association; www.nema.org– NEMA, created in the fall of 1926 by the merger of the Electric Power
Club and the Associated Manufacturers of Electrical Supplies, provides a forum for the standardization of electrical equipment, enabling consumers to select from a range of safe, effective, and compatible electrical products.
• ANSI: American National Standards Institute; www.ansi.org– The American National Standards Institute (ANSI) is a private, non-
profit organization that administers and coordinates the U.S. voluntary standardization and conformity assessment system
• IEC: International Electrotechnical Commission. – IEC is the authoritative worldwide body responsible for developing
consensus global standards in the electrotechnical field
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Standards
• IEEE: Institute of Electrical and Electronic Engineers; www.ieee.org– The IEEE is a non-profit, technical professional association
for Electrical and Electronics Engineers.
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Power Distribution Systems
Power Distribution Systems Consist of:• MCC or Motor Control Centers
• Loop Switches
• Transformers
• Voltage Regulators
• Capacitor Banks
• Circuit Breakers
– OCB’s, Oil Circuit Breakers
– Air Circuit Breakers
• Disconnect Switches
• Fuses
• Starters and Combination Starters
• Power Monitoring and Control Systems
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Switch Gear
Power Distribution System Example: 13.2 kV from Utility
13.2 kV from Utility
Power Distribution Systems
Low Voltage Systems:
• Up to and including 600 VAC or DC
Medium Voltage Systems:
• From 600 V up to 1,000 V, 1 KV
High Voltage Systems:
• From 1,000 V up to 800 KV
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Power Distribution Systems
MCC’s or Motor Control Centers• Allen-Bradley Slide Show• Other Sources:
– Square-D
– ABB
– Seimens
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Sections• 20” (508mm) wide
standard
• 15” (381mm) or 20” (508mm) deep
• 90” (2286mm) high standard,
– 71” (1790mm) high available
• Front mounted or back-to-back
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Front MountedBack-to-Back
NEMA Enclosure Types
• Type 1
• Type 1 with gaskets
• Type 12 (also instainless steel)
• Type 3R
• Type 4 stainless steel
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NEMA Type 1
NEMA Type 4
Bus Connections• At least two bolts
– Horizontal-to-vertical– Horizontal splices – Extra bolt ensures integrity
• Front accessible
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Horizontal to Vertical Connection
Horizontal Ground Bus• 1/4” x 1” (6.4mm x
25.4mm) or 1/4” x 2” (6.4mm x 50.8mm)
• Unplated or tin-plated copper
• Located in wireway– Top or bottom– Top and bottom
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Vertical Ground Bus• Plug-in ground bus
– Steel (standard)– Copper (optional)
• Unit load ground bus optional– Copper– For easier
termination of ground wires
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Unit Load Ground Bus
Plug-in Ground Bus
Incoming Lug Compartment
• Top or bottom
• Straight pull for cables
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Main Fusible Disconnect
• Top or bottom
• Frame mounted
• 600A-2000A utilize “Bolted Pressure Switch”
• Visible blade
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BoltedPressure
Switch
Main Circuit Breaker
• Top or bottom
• Frame mounted
• Ground fault protection available
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Space Factors
• One space factor equals 13” (330mm)
• Six space factors per section
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78” (1981mm)
13” (330mm)
Full Voltage Non-Reversing Starter Units
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1.5 Space Factor Dual Size 1
(8 starters/section)
1.0 Space Factor Size 1
(6 starters/section)
0.5 Space Factor Size 1
(12 starters/section)
Stab Assembly• Housing
– Isolates incoming phases acting as a fault barrier
• Stabs– Tin-plated– Rated 240A– Directly crimped– Steel spring backed– Free-floating and
self-aligning
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Stab Assembly
Unit Grounding Provisions
• Unit ground stab– Used with unit plug-in
ground bus– Copper alloy (standard)– Solid copper (optional)
• Unit load ground connector– Used with unit load
ground bus– Solid copper– For easier termination of load
ground wire
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Optional Plug-in Ground Stab
Unit Load Ground
Connector
Standard Plug-in Ground Stab
Unit Handle
• Remains in control of disconnecting means
• Positive status identification
• Interlocked with door
• Padlockable
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Unit Interlock
• Prevents inserting or withdrawing unit with handle in ON position
• Padlockable
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Bulletin 2100 Unit Components
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Bulletin 500 NEMA Contactor
Fusible Disconnect or Circuit Breaker
Bulletin 1492 Pull-Apart Terminal Blocks
Bulletin 592 Melting
Alloy or Solid-State
Overload Protection
Pilot Devices
• Generally housed in control station
• Bulletin 800T – up to 3
• Bulletin 800MR – up to 8
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Bulletin 800T
Bulletin 800MR 0.5 Space Factor Unit with Pilot Devices
Variety of Units
Plus: Full Voltage Contactors, Two-Speed Starters,Reduced Voltage Autotransformer Starters
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Full Voltage Non-Reversing Starters
Full Voltage Reversing Starters
Feeders
Lighting Transformers
Variable Frequency Drives - Up to 250HP
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Bulletin 1305
Bulletin 1336 PLUS or Bulletin 1336 PLUS II
Smart Motor Controllers (SMCs) - Up to 500A
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SMC Dialog Plus
PLC I/O Chassis
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Bulletin 1771
SLC-500
Bulletin 1771 Full Section
Metering Units
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Analog Metering Unit Powermonitor II Metering Unit
Bulletin 2400 Units
• Application-rated
• IEC components
• Reduced space
• IEC standards– Units – IEC 60947– Sections – IEC 60439-1– Witness tested by:
• KEMA• ASTA
– CE rating upon request
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Bulletin 2400 Components
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Bulletin 100 IEC Contactors
Bulletin 193 IEC Overload RelayFusible
Disconnect or Circuit Breaker
Bulletin 800E IEC Pilot Devices
FacilitiesProject Engineering
Bobby Rauf ©
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Topics
• Project Flow Chart
• Project Gantt Chart
• Cost Reduction, Repair vs. Replace Decisions
• Life Cycle Cost, With Time Value of Money
• Cost Justification Case Study
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Project Flow Chart
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ENGINEERING PHASE
Develop Functional Specifications
Develop Project Schedule
Procurement Planning
Preliminary Engr.
CONSTRUCTION PHASE
MAINT. OPERA-TIONS
Perform Value / Cost Analysis
Detailed Design
Develop Bid Packages
Obtain Bids and Award Contracts
Constructibility Reviews
Mobilization Planning
Safety and Security Plan
Long Lead Procurement
Construction and Field Engineering
Site Safety and Security
Testing, Start-up & Commissioning
Maintenance Program Development
Training Program Development
Issue Fab. & Instl. Drawings
Construction SupportAs Built
Drawings
Material & Equipment Tracking, Expediting & Receiving
Maintenance and Operations Training
Proj. Phases
ENGINEERING
PURCHASING / PROCUREMENT
CONSTRUCT-ION
MANAGEMENT
OPERATIONS &MAINTENANCE
Tasks/Resp.
Req. Funds for Engr. & Long Lead
Develop and Maintain Project Schedule
Develop Preliminary Budgetary Estimates
Develop Detailed Estimates Manage Changes in Scope of the Project
PROJECTMANAGEMENT
Project Gantt Chart
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Cost Reduction, Repair vs. Replace Decisions:Repair vs. Replace decisions involve comparison of the life cycle cost of
equipment under two mutually exclusive scenarios: a) Life Cycle Cost if the equipment is replaced.b) Life Cycle Cost of the piece of equipment in question if it is
repaired.
Life Cycle Cost:Total cost of owning and operating a piece of equipment over its
expected life. This cost would consist of the following:– Initial cost or investment – Total preventive, predictive and other typical maintenance cost
over the life span of the equipment– Fuel, electricity or other energy cost over the life of the
equipment. This would take into account the efficiency of equipment.
– Opportunity cost or lost production if the equipment malfunctions.
– Depreciation: D (S/L) = (Original Cost – Salvage Value) /Life in # of Years
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Cost Based Motor Repair vs. Replace Decisions:
Sample Problem,
A 100 HP, 480 VAC, 3-Phase blower motor has experienced a ground fault due to winding failure. This motor has been repaired/rewound twice before. The motor has lost 5% of its efficiency during each of the past two (2) rewinds,due to core losses. The maximum actual load on the motor is 90 HP.
- A typical rewind or repair service, for a 100 HP motor is $1,600. - A new premium efficiency motor cost, approximately, $3,400. - Electricity cost at this facility averages $0.05/KWH. - Assume initial efficiency of 96% and a power factor of 0.9.
a) What is the cost of owning, maintaining and operating this motor over a period of 10 years?
– Assume that the motor experiences a ground fault at the 5th year, 8th year and the 10th year.
– Assume 24-7 operation and an average efficiency of 95% over 10 years. Assume that the electricity cost stays constant over 10 Years.
– Assume Lost Production Cost and Maintenance Labor Cost of $ 3,000 per Failure.
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Cost Based Motor Repair vs. Replace Decisions:
Original Efficiency of the Motor is = 96%Motor Efficiency after 1st Rewind = 96% x (1 - .05) = 91.2%Motor Efficiency after 2nd Rewind = 91.2% x (1 - .05) = 86.64%Motor Efficiency after 3rd Rewind = 86.64 HP x (1 - .05) = 82.31%Energy Cost, 1st Five (5) Years
= 100 HP x 0.746 KW/HP x 24 x 365 x 5 / 0.96 x 0.05 = $ 170,181 Line Current = 104 AmpsAnnual Energy Cost = $ 34,036
Energy Cost, After 1st Rewind, for Three (3) Years= 100 HP x 0.746 KW/HP x 24 x 365 x 3 / 0.912 x 0.05 = $ 107,483 Line Current = 109 AmpsAnnual Energy Cost = $ 35,828
Energy Cost, After 2nd Rewind, for Two (2) Years= 100 HP x 0.746 KW/HP x 24 x 365 x 2 / 0.8664 x 0.05 = $ 75,427 Line Current = 115, An 11% Rise in Line CurrentAnnual Energy Cost = $ 37,713
NOTE: After the second rewind, the motor Line Current has risen by 11%.QUESTION: After two (2) Rewinds, is the operating level of Line Current
approaching the Design Limit of the Conductors and the Circuit Breakers?
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Life Cycle Cost of Owning and Operating a 100 HP Motor
Life Cycle Cost Comparison Without Time Value of Money Consideration:
Scenario (1):Rewind Twice, then Replace at 3rd Failure:=( $170,181+$107,483+$75,427)
+($1,600+$1,600+$3,400)+(3)x($3,000) = $ 368,691
Scenario (2):Replace upon 1st Failure:=( $34,036 x 10) + ($3,400+$3,400) + (2)x(3000) = $ 353,163
Replacement Option Life Cycle Cost is Favorable By:$15,528
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Energy Cost
Rewind & Repl. Cost Lost Prod. Cost
Life Cycle Cost of Owning and Operating a 100 HP Motor
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Life Cycle Cost Comparison Based on Time Value of Money:
Discount Rate: 10%
Scenario (1): Rewind Twice, then Replace at 3rd Failure:Year #1 Year #2 Year #3 Year #4 Year #5 Year #6 Year #7 Year #8 Year #9 Year #10
Actual Energy Cost: -34036 -34036 -34036 -34036 -34036 -35828 -35828 -35828 -37713 -37713Purchase & Rewind Cost -3400 -1600 -1600Lost Prod & Maint. Cost: -3000 -3000 -3000
Cash Flows: -37436 -34036 -34036 -34036 -34036 -40428 -35828 -40428 -37713 -40713
Present Value of EC: ($223,871)
Scenario (2): Replace Upon 1st Failure:Year #1 Year #2 Year #3 Year #4 Year #5 Year #6 Year #7 Year #8 Year #9 Year #10
Actual Energy Cost: -34036 -34036 -34036 -34036 -34036 -34036 -34036 -34036 -34036 -34036Purchase & Rewind Cost -3400 -3400 0Lost Prod & Maint. Cost: -3000 0 -3000
Cash Flows: -37436 -34036 -34036 -34036 -34036 -40436 -34036 -34036 -34036 -37036
Present Value of EC: ($216,997)
Cost Diff. Sceraio (1) vs. Scenario (2): ($6,874)
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Cost Justification Example:
NOTE: This is a simplified version of customary financial analysis conducted for development of Project Justification. - Assume that the Investment or Project is Commissioned into Service at the Beginning of Year 1
1. Annual Utilities Cost, @ Assumed Annual Discount $0.05/KWH; 24/7Operation (Interest) Rate: 10%on Equipment to be Replaced (32,675)$
Initial Cost of Project: Proj./Eq. Life Operating Years & Cash Flows200,000$ 10
Year 2nd 3rd 4th 5th 6th 7th 8th 9th 10thDescription: 1 2 3 4 5 6 7 8 9 10
COSTS:
Write-off of Existing Investme (50,000)$ @ Book Value
2. Depreciation Cost (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$
3. Taxes @: 0.65% (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$
SAVINGS:
1. Utilities / Energy: 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ 4,901$ Eff. Improvement. 15%
2. Productivity Improvement: 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 9,802$ 30%
3. Est. Annual Maint. Cost 1,000$ 1,000$ 1,000$ 1,000$ 1,000$ 500$ 500$ 500$ 500$ 500$ Reduction:
4. Reduced Safety Incident 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ 92,500$ Rate, Shoulder, Back or Arm Injuries *
Net Annual Cash Flows: 36,904$ 86,904$ 86,904$ 86,904$ 86,904$ 86,404$ 86,404$ 86,404$ 86,404$ 86,404$
FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEquipment Replacement Example
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Cost Justification Example:
Year 2nd 3rd 4th 5th 6th 7th 8th 9th 10thDescription: 1 2 3 4 5 6 7 8 9 10
Net Annual Cash Flows: 36,904$ 86,904$ 86,904$ 86,904$ 86,904$ 86,404$ 86,404$ 86,404$ 86,404$ 86,404$
PV's, Present Values: $33,549 $71,821 $65,292 $59,356 $53,960 $48,773 $44,339 $40,308 $36,644 $33,312
NPV (1) $487,354 Sum of ALL Present Values from the ten Year Life of the Equipment or Project
NPV (2) $487,354 Excel Based Calculation
IRR 41% Average of ALL Cash Flows, or Net Savings Generated By the Project, During its Ten Year Life Expectancy Divided by the Total Investment
ROI: 43% Net Inc./Avg.Total Assets:
Payback Period, in YEARS: 2.31 Total Investment Divided By the Average of Cash Flows
* Note:Savings Based on Reduced Safety Incident Rate Include The Following Cost Assumptions:1) Approx. Cost for Back Surgery: 25,000$ 2) Approx. Cost for Carpel Tunnel Surgery: 15,000$ 3) Approx. Cost for Shoulder Surgery: 25,000$ 4) Approx. Cost Disability Settlements: 120,000$
Total 185,000$ However, for this calculation, the annual cost assumed for this category 92,500$
FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEquipment Replacement Example
Industrial Safety and Safety Systems
Bobby Rauf ©
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Topics
• Safety Certifications in Industrial Environment
• Safety Products
• Safety Video
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Safety Certifications in Industrial Environment:
• Look for the following safety related certifications, tests or labels on “off the shelf” equipment:– UL (United Laboratories) Listed– IEC, International Electrotechnical Commission– IEEE, Institute of Electronic and Electrical Engineers– NEC, National Electrical Code– IP Rating– CE Certification
• On custom engineered systems or equipment, look for Safety Compliance Statement from the manufacturer, engineering firm, general contractor or system integrator.
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Safety Products
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Safety Products
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Safety Mat + Controller
Safety Light Curtain
Safety Relays
Key / Solenoid Interlock Switches
Cable PullSwitches
Safety Buttons
Trapped Key
Safety Contactors & Control Relays
Safety PLC
Safety Laser Scanners
Safety Limit Switches
Safety Guard Edges
Safety EOI
Network Communications
Safety E-stop Devices
• E-Stops– Available in 30mm & 22mm sizes– Metal and plastic construction– Meet EN418 and IEC 60947-5-5
standards– Push-pull, push-pull/twist release, illuminated,
or key-operated devices• Self Monitoring Contact Blocks
– For use with 800T & 800E E-Stops– Patented technology improves reliability and safety– If contact block becomes separated from E-stop,
monitoring circuit automatically opens and shuts down the controlled process
– Essentially eliminates contact separation concernsfrom improper installation, damage or high-vibrationapplications
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Series 800T/800E & Self Monitoring Contact Blocks
Zero-ForceTM Touch Buttons
• 800Z GP (General Purpose) Line• 800Z HI (Heavy Industrial) Line
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Global Mounting Offered Exclusive 22.5 mm line &
standard 30.5 mm line
Superior Rigid Guards Largest ergonomic interface NEMA and IP rating remain
when guard is used Optional Guard Colors -
Black, Red, Green and Yellow
BACK
Prosafe™ Trapped Key Interlocks
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Solenoid Release
Access Locks
Key Exchange
Miniature ValvesPower IsolatorsBACK
POC (Point of Operation Control)
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Two box Design General Purpose Category 4 (control reliable) Safety
Light Curtain Can operate in Guard only mode (Transmitter/Receiver) Power supply and safety relays may be required
depending on the application 14mm resolution finger protection
Scanning range 6m (20ft) 30mm resolution hand protection
Scanning range 18m (60ft) Fast response time - 15ms Protective Heights from 300 mm (12”) to 1800mm (70”)
in 150mm increments Options with 440L-M8100 interface
Manual and automatic restart Fixed Blanking / Floating blanking Muting PSDI (Presence Sensing Device Initiation) User stored configurations Two sets of optic heads can be connected to one
controller IP 65 enclosure rating Mini quick disconnect
Safe Shield
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New Generation Point of Operation Category Type 4 Safety Light Curtain(EN 61496)
Software Configured Features (RS 232 interface) EDM (External Device Monitoring) Internal or External integrated Restart
interlock Fixed Blanking/Floating Blanking
Maximum of Four Blanking fields at once
Reduced Resolution Cascadable
Up to 3 segments can be connected (Host/Guest/Guest)
Each segment is individually programmed
CE certified, cULus listed DeviceNet Light Curtain Interface Metal M23 style 12 pin connector IP 65 Beam Coding ( non-coded, 1 or 2 beam code
patterns)
SafeShield DeviceNet
• DNet module can be interfaced to any SafeShield product at any time
• Diagnostic information can be transferred via DeviceNet (Output status / EDM active / Restart required / Device faulted / Weak signal / Blanking selected)
• DNet Communication via DNet Module (Black)
• SCD Software for L.C. Configuration only, not for DNet
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DCPowerSupply
PAC (Perimeter Access Control)
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Enclosure rating IP 65 24Vdc Two box Design Complies with requirements for type 4 Meets CE requirements as pr EN 50 100 Ambient operating temperature 0 ... + 55
°C Response time - 20 ms Scanning range 0.5 – 70m Min. resolution 73 mm Number of beams 1-4 2 OSSD PNP Semiconductor outputs Mini Style connectors Integral Muting Module available Margin Indication
An output turns on when lens are dirty
AAC (Area Access Control)
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Long Scan Range up to 70M (230Ft.)
Die Cast Aluminum Housing
Two Ranges available
- .5M to 18M (19.5” to 59”)
- 15M to 70M (4’ to 230’)
Easy Installation
Heated Front Screen, I.e. can be used in outdoor applications
Fast response time 22ms
24vd/115vac standard / 230vac (special order)
Built in monitored safety relays
- 2 NO/1NC / 2A Max switching Current
IP 65 enclosure rating
Operating temp. -25°C to 50°C
PG connector IP 67
BACK
Cable Pull Switches
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Lifeline 4
Lifeline 3
LRTS
Lifeline 2
BACK
Safety Laser Scanner
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Future Product Release forthcoming
BACK
Hinge & Tongue Interlock Switches
•Trojan QD
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Elf
Trojan5
Cadet
Trojan5GD2
TrojanEX
ISOMAGRotocam
Sprite
Bolt Lock
MT-GD2
Noncontact Magnetic Switches
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FerrogardSentinelFerrotek
Ferrocode
Sipha
Multiple Switch & Magnetic Actuators - Custom matched
Defeat-Resistant Non-Contact Switch
Wire to Safety Relay to check the switch’s operation
Air Gap Actuation Range ~0.375 -0.75 inch
High Tolerance to misalignment Electrical Configurations: NO. NC.
SPDT Advantage: Magnets can be epoxied
Key Interlock Solenoid Switches
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Spartan
TLS GD2
Atlas 4
Atlas 5 w/Trap Key
Atlas 5 w/Key
CU1 (Time Delay)CU2 (Stop Motion)CU3 (Back EMF)
BACK
Safety Limit Switches
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2-Circuit, Snap-Acting contact design 802T Plug-in Family of products
— Mounts and operates in accordance to NEMA style limit switches.
— Rugged metal body— Meets or exceeds durability requirements of
NEMA style Limit Switches– Longer Life and durability as compared
to IEC style Limit Switches Snap Acting contacts for fast change over and no
“contact tease” Normally Closed “safety contacts” are forced open
when switch is actuated Lower travel to operate Direct Opening Action
feature when compared to IEC style NEMA 6P enclosure rating Same Length Mounting Screws QD and pre-wired versions available cULus and CE certified and approved
BACK
GuardMat™ Safety Mats
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Controllers
Mats
Edge Trim Uniting TrimBACK
GuardEdge™ Safety Edges
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Component Parts
Profiles/Rails and Controllers
BACK
MobileView Guard G750 Terminal
• Category 3 Safety • Maintain interface to control system with access to
safety system• 3-position enable switch
– Released, enabled, clenched– Sense both failure modes (dropped & panic)
• Optional Emergency Stop Switch• Ergonomic design
– Multiple hand positions– Light weight– Cable can exit housing on either side
• Thin Client Connection – Embedded 10 Base T Ethernet
• Rugged industrial connection cable– Single cable carries all signals
– Easy connect/disconnect
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Safety PLCs
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GuardPLC 2000 and 1200 shipping since August– TÜV Certified (Entire System) - IEC 61508 SIL 3, DIN
VDE 19250 AK6, EN 954-1 Category 4, – UL Listed– Primary Target Market - Machinery Safety
GuardPLC 2000 - 6 I/O slot, modular design– 24 Input / 16 Output digital – 8 Channel Analog Input & Output (12 bit resolution)– 2 Channel HSC (100kHz, 24 bit)
Guard 1200 - packaged design– 20 Inputs / 8 Outputs + 2 HSC Inputs (100khz, 24 bit)
Communications – Proprietary GuardPLC Ethernet + ASCII– Peer to Peer Safety Communications
RSLogix Guard Software (2 versions)– Lite and Professional Versions– Windows NT/2000– RSLogix “Look & Feel”– IEC 1131 Function Block Programming – User Defined Function Block Capabilities (1755-PCS)
GuardPLC Communications
• GuardPLC Connectivity to RA PLC’s via RS-232 ASCII
• Peer to Peer via GuardPLC Ethernet - Series B Firmware (May 2002)– Enables Safe Communications Between GuardPLCs over the proprietary
GuardPLC Ethernet – Any combination of GuardPLC 2000s and 1200s
• Limited by maximum tag count of software• Maximum 650 tags with Professional Software package (1755-PCS)
– Enables Utilization of one or more controllers as ‘remote I/O’ units• Easy to Implement - No program needed in remote I/O units, just tag setup• GuardPLC 1200 - Full tag count for RIO just under 150 tags
– Tags for I/O points and full diagnostics available to Supervisory GuardPLC
– Less tags required if I/O or diagnostics are not fully utilized - Typically 75 to 100 Tags
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BACK
Network Communications
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Standard Communications for Diagnostics Purposes Several Safety Products can be Connected to DeviceNet
– See you Local Representative for the current list of products GuardPLC’s Can Communicate to Standard PLCs
– ASCII to PLC Front Port Connectivity - SLC, PLC-5 and ControlLogix– Example Application Code is Available from RA
Safety Communications: Peer to Peer via GuardPLC Ethernet - Series B Firmware (May 2002)
– Safe Communications Between GuardPLCs via GuardPLC Ethernet – Enables Utilization of One or More GuardPLC’s as ‘Remote I/O’ Units
Requires only Tag Configuration - No Programming of Remote Units RA is Committed to Supporting Safety in the NetLinx Communications Architecture
– Target Availability for DeviceNet Safety is 2004
BACK
Safety Relays
• Emergency Stop Relays– Monitors the E-stop Circuit– Monitors Safety Gate Limit
Switches– Monitors Light Curtains– Monitors Rope Pull Switches
• 2-Hand Control & Safety Gate Monitors
– 2-Hand Anti-tiedown & Anti-repeat relay
– Controls machine from safety gate limit switches
• Provides additional safety contacts
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Two Hand Controllers
Single Channel
Dual Channel
BACK
Safety Contactors & Control Relays
• Safety Contactors: – Reversing & Non-reversing Assemblies– 9..85A (60HP)– AC & DC Coils
• Safety Control Relays:– 8 Pole Assemblies– AC & DC Coils
• Features:– Meets IEC 947-5-1 “mechanically
linked/positively guided contacts”– Meet GM NAO DHS-1 “MPS”
Requirements – SUVA Third Party Certified– Auxiliary Contact Blocks Permanently
Fixed
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100S Safety Contactors
104-C ReversingSafety Contactor
700S-P700S-CF
BACK
HVAC in Industrial/Commercial Facilities
Bobby Rauf ©
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Topics
• Definitions of common HVAC terms
• Maintenance and Performance Tips
• HVAC Systems; The Refrigeration Cycle
• Automated HVAC Systems
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Definitions
• HVAC: Heating, Ventilation and Air Conditioning• Dry Bulb (DB): Temperature read or measured with a standard
thermometer.• Wet Bulb (WB): Wet bulb is the temperature measured or
indicated by a thermometer whose bulb is covered by a water saturated wick and exposed to a stream of air moving at, approximately, 100 ft./min.
• Relative Humidity (RH): Relative humidity is the ratio of the amount of vapor in the air, at a specific set of conditions, to the water vapor that could be held when saturated.
• Dew Point (DP): This is the temperature at which moisture will start to condense from the air
• Enthalpy (h): Enthalpy is the heat content of a system (air). It is measure of the amount of heat contained in a system.
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Maintenance & Performance Tips
• Chillers: Periodic cleaning of Evaporator and Condenser Tubes– Install automatic tube cleaning systems in evaporator and condenser
tubes.
– Maintain insulation in a good state of repair.
• Air Washers:– Regular PM or cleaning of the Eliminators.
– Regular PM, repair or replacement of water spray nozzles.
• Cooling Towers: Periodic cleaning of Cooling Towers– Maintain water contact surfaces free of organic build up.
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HVAC Systems; The Refrigeration Cycle:
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Condenser
Compressor
Evaporator
Expansion Valve
High Pressure LiquidHigh Pressure Vapor
Low Pressure Liquid
To/From Cooling Load
Vapor
To/From Cooling Load
Automated HVAC Systems
• Many manufacturers:
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Terminology
• At a conceptual level, a DDC, Direct Digital Control, system can be thought of as consisting of three groups of components: inputs, outputs, and intelligence (Fig. 1). The individual inputs and outputs are usually considered by the system to be "points"--a very useful, logical concept that we will come back to later.
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Terminology
• Inputs. Input points can be divided into two broad categories--analog inputs (AI) and digital inputs (DI). – Analog input (AI): a point that is able to read a continuously
variable signal. Examples of analog input devices are temperature sensors, humidity sensors, pressure sensors, current and voltage sensing devices, and gas concentration sensors.
– Digital input (DI): a point that will accept only two states of information for the system, such as on-off or open-closed. Examples of digital input devices are dry contacts to sense relay status and fluid level sensors.
– Many manufacturers arrange the input circuitry in the intelligence so that the inputs are universal--i.e., they can be configured in software to recognize a digital or analog input device without having to change the panel hardware. This provides flexibility and
cost advantages.
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Terminology
• Outputs. Output points, like inputs, can be divided into the same two categories of analog and digital, with the same defining characteristics of two states for digital devices and continuously variable for analog devices.– Analog outputs (AO) most commonly drive valve or damper
motors. 0-10Vdc and 4-20 mA are the most common signals
– Digital outputs (DO) almost always switch relays of some sort, whether starting motors, turning on lights, or moving two-position actuators.
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Terminology
• Controlled devices. Controlled devices are the valves, dampers, and relays that the outputs act on to affect the mechanical systems we want to control. – Most analog-controlled devices are nonlinear in their action on
the fluids they control. An example is the commonly used butterfly valve. This used to be a huge issue for design and control of mechanical systems, but it doesn't really matter now that the conversions are in software.
– In fact, it has advantages in terms of not having to select devices for their linear characteristics. Nonlinear devices can provide operating cost benefits from lower average pressure drops, for example.
– However, it is left up to the controls engineer to have enough software and hardware expertise to compensate for sometimes questionable mechanical equipment selections.
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Terminology
• Direct Digital Control. (DDC) The electronic measurement of an input (process) variable, comparison of the measured value to a setpoint to compute error and software logic to determine an output value that is transmitted to a control device (i.e.. Damper, valve etc.) to cause the desired action on the input.
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Terminology
• Direct Digital Control: (DDC)
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M
DDC Controllerw/Software
ElectronicSensor
M AB
AB4-20 mA I/P 3-15 Psi
Thermistor/RTD
4-20 mA
Current toPneumaticTransducer
Terminology
• Protocol: A defined set of instructions for programmer’s to allow computers to transfer information
• TCP/IP: Transport Control Protocol/Internet Protocol
• HTTP: Hypertext Transport Control Protocol
• HTML: Hypertext Markup Language
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Terminology
• DDE: Dynamic Data Exchange. A Microsoft standard for communications between Windows programs
• OPC: OLE for Process Control. The current standard for control vendors to allow open communications from Windows based programs to their systems. Replaces DDE as a method of communicating with control systems using a Windows technology standard.
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Automated HVAC Systems
• Some common elements– PC based “front ends”– Local area networks– Global level controllers– Equipment level controllers – Terminal unit controllers – Operating software– Field devices (sensors, transducers etc.)
• Lets look at each one….
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Automated HVAC Systems
• Field devices– Temperature sensors
• Thermistor most prevalent
• RTD
• Solid state temp sensor (AD592)
• Thermocouple
• Some vendors require 4-20 ma transmitter for field device
• +/- .5 deg f accuracy/repeatability possible
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Automated HVAC Systems
• Field devices– Humidity sensors
• Resistive type (General Eastern)
• Capacitive type (Hy cal)
• Require 4-20 ma transmitter
• 3-5 % accuracy most common
• 2 % available ($$$)
• Require calibration (once a year)
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Automated HVAC Systems
• Field devices– Air Pressure sensors
• For VAV applications most vendors build into controller
• 4-20 ma most common
• Hard to calibrate in field
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Automated HVAC Systems
• Field devices– Water Flow meters
• Requires understanding of mechanical system for proper operation
• Most difficult sensor to apply
• 4-20 ma most common
• Get what you pay for $$$$$
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Automated HVAC Systems
• Field devices– Air Flow Meters
• Convert static/velocity pressure to electronic signal
• Most use and averaging principal
• Can be expensive $$$
• Industrial versions available with purge capability
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Automated HVAC Systems
• Field devices– E/P or I/P transducers
• Convert electronic signal to pneumatic (3-15 Psi)
• Some have feedback of branch pressure
• Some are zero use (no bleeding of air) when in steady state
• Usually panel mounted
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Automated HVAC Systems
• Field devices– Pneumatic actuators
• Convert pneumatic signal
to mechanical force to
open valve or damper.
• Most bang for $$$
• Common in retrofits
• Can have a fast response with positioner
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Automated HVAC Systems
• Field devices– Electric actuators
• Slow responding
• Expensive $$$
• Accurate (not much slop)
• Most prevalent in terminal unit control (VAV boxes, roof top units etc. )
• Take 4-20 ma or 0-10 VDC or PWM directly from controller
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Automated HVAC Systems
• Field devices– Lighting Control
• Intelligent Breakers
• No need for outboard relays
• Interface through RS232/RS485
• Lights can be Zoned/Grouped
• Phone Override capability
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Automated HVAC Systems
• Field devices– Indoor Air Quality
• Measurement range: Carbon Monoxide 200 PPM, Carbon Dioxide 2000 PPM
• Outputs are 4-20 mA or 0-10 VDC
• Wall and duct mount configurations
• Use to regulate outside air dampers for air quality
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Automated HVAC Systems
• PC based “Front End”– computer with Windows Software
• Graphic screens for operator interface
• Real time data presented
• Operator input for setpoint/schedules etc.
• Alarm management
• Trending/history functions
• Invaluable troubleshooting aid
• Modem communications from off-site
• Diagnose before dispatching service personnel !!
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Automated HVAC Systems
• Color Graphics– Allow accurate presentation of data from
Mechanical equipment and controlled area/process
– Real time data presented
– Operator input for setpoint/schedules etc.
– Alarm notification
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Air Washer Control Screen - EMS
Automated HVAC Systems
• Trending and Data Presentation– Allows collection of data to hard drive for
storage
– Provides for secure way of archiving data
– Allows for analysis of data while on-line and also offline in Excel, and other spreadsheet type programs
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Air Washer Discharge Temperature Trend –EMS
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Chiller Load EMS System Screen
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Automated HVAC Systems
• Alarm Management– Allows collection of alarm data to hard drive
for storage
– Should be used for “real” alarms. Alarm limits that are too tight become nuisances and get ignored.
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Chilled Water Loop Screen – EMS System
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Air Washer Safeties/Status /Limits
Automated HVAC Systems
• EMS Control Routines– Scheduled start/stop
– Optimized start/stop
– DDC Temperature Control
– Enthalpy control
– Drybulb economizer control
– Temperature setback/setup
– Night time purge of facility
– Supply air setpoint reset
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Automated HVAC Systems
• EMS Control Routines– Boiler/Chiller optimization
– Custom strategies such as ice making systems
– Lighting control
– Demand Limiting
– Cogeneration Control
– Load Forecasting
– Utilities Submetering/Billing
– Metering and Verification
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Automated HVAC Systems
• EMS Control Routines– Scheduled Start/Stop - Starting and stopping
equipment based upon time of day, and the day of the week.
• Newer systems include tenant override and tracking
– Optimum Start/Stop - Adjust equipment operating schedule based upon space temperature, Outside temperature, humidity etc
• Newer systems constantly fine tune start/stop times
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Automated HVAC Systems
• EMS Control Routines– Enthalpy Control - Utilize outside air for cooling
whenever OA enthalpy is less than RA enthalpy• Can cause humidity problems in some systems
– Drybulb Economizer - Utilize outside air for cooling whenever OA temperature is less than the required mixed air setpoint
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Automated HVAC Systems
• EMS Control Routines– Temperature Setback/Setup - Lower the space
heating setpoint and raising the space cooling setpoint during unoccupied hours
• Usually combined with Optimum Start/Stop
– Night Time Purge - Purge the facility of stagnant humid air before startup to take advantage of cool morning temps.
• Can cause humidity problems in certain climates
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Automated HVAC Systems
• EMS Control Routines– Supply Air Setpoint Reset - Selects the
zone/area with the greatest heating/cooling requirement and establishes the minimum hot deck and cold deck temperature differential that will meet the requirement.
– Boiler/Chiller Optimization - A combination of Lead/Lag and chiller/boiler selection to run the most efficient combination of equipment to meet the building load.
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Automated HVAC Systems
• Primary/Secondary Chiller Plants– Useful in large distribution systems i.e..
Industrial, Campus, Airports etc.
– Reduces pumping Hp through use of VFD’s on secondary pumps
– Requires good understanding of mechanical design of HVAC units and chiller plants
– Is best controlled through DDC/BAS system
– Can be time consuming to get control sequence “right”
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Automated HVAC Systems
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Automated HVAC System – EMS Screen
Automated HVAC Systems
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Automated HVAC Systems
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Energy Conservationin Industrial / Commercial
Facilities
Bobby Rauf ©
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Topics
• Definition
• Energy Unit Conversions
• Energy in its Common Forms
• Energy Audits
• Areas of Potential Savings
• Financial Justification for Energy Conservation Projects
• Metering, Monitoring and SCADA Systems
• Power Bill Calculation
• Automated Energy Management Systems
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Definition:
• Energy: Capacity to perform work. Note: Energy is not the same as Power.– Formula for Energy: Energy = Force x Distance; or, E =
Work = F x S
– Units for Energy: • British or American: BTU’s; or British Thermal Units.
• Also, under the British System: foot-pounds or ft-lbf or horsepower-hours, or hp-hrs
• Metric: N-m; or Joules; 1.0 J = 1 N-m
• Also, under the Metric System: Kilowatt-hours, kWh
• Erg; from Greek word “ergon,” meaning: work; 1 erg 10-7Joules. One erg = Force of 1 Dyne applied through a Dist. of 1 cm.
• Other units for energy: Calories, kilocalories, therms, Evs and MEV
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Energy Unit Conversions:
• BTU’s to kWh and KWh to BTU’s:– 1 BTU 1 BTU x (2.928 EE –4 kWh/BTU)
0.0002928 kWh
– 1 kWh 1 kWh x (3413 BTU/ kWh) 0.0002928 kWh
• MMBtu’s to Btu’s:– 1 MMBtu’s 1 MMBtu x (1000,000 Btu/MMBtu)
• MWh to kWh:– 1 MWh 1 MWh x (1000,000 kWh/MWh)
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Energy Unit Conversions:
• BTU’s to tons and tons to BTU’s:
– 1 BTU 1 BTU x (8.333 EE-5 tons/BTU) 0.00008333 tons
– 1 ton 1 ton x (12,000 BTU/ ton) 12,000 BTU’s
• Deca Therms to BTU’s:
– 1 dT 1 dT x (1,000,000 BTU/dT) 1,000,000 BTU’s 1MMBTU’s
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Energy in Its Common Forms:
Energy in various plants and facilities exists in the following most common forms:
1. Electrical Energy (kWh or MWh): The most direct uses of electrical energy are:
– Lighting.– Motor Loads: Fans, Blowers, Air Compressors, HVAC Equipment,
Conveyors, Pumps, Manufacturing Equipment Driven by Motors– Electrical Heating Elements in Resistive Heating Applications– IR, or Infra-red Heat– Electronic Equipment; through built-in power supplies– RF,or Radio Frequency Loads – Microwave Loads– Construction and Fabrication Equipment– Electromagnetic Control Devices
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Energy in Its Common Forms, contd:
2. Gas and Petroleum (BTU’s or Decatherms):Natural Gas, Propane, Diesel, Gasoline, Kerosine and other types of fuels. The most direct uses of fuels are:
– Electrical Power Generation– Heating– Transportation and Hauling Equipment– Construction and Fabrication Equipment
3. Steam, an indirect form or energy4. Compressed Air, an indirect form or energy5. Stack Heat, a usable byproduct of heat energy
application in Ovens and Furnaces, etc.
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Energy Audits:
• Energy audits identify major areas of energy usage in a facility and quantify energy productivity in those areas.
– Final end product of most audits include a list of energy conservation opportunities
– In certain cases audits are taken to the extent of developing proposals and economic justification of potential energy conservation projects
– Some Energy Consulting Firms provide comprehensive turnkey services by taking the results of an audit and proposing, guaranteed, turkey installation and commissioning of energy conservation measures
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Energy Audits:
• In large facilities, with high diversity in type of equipment, for audits to be more focused and productive, they should be segmented as follows:
– Electrical Audit; to be conducted by a firm specializing in Electrical Engineering
– Compressed Air Audit; to be conducted by a firm specializing in Mechanical Engineering Discipline
– HVAC Audit; to be conducted by a firm specializing in HVAC or Mechanical Engineering
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$$ Areas of Potential Savings $$:• Lighting: When possible, implement energy conservation
through the following measures:– Perform a lighting audit. Does your facility meet, fall short of or
exceed the lumen or foot-candle requirements for specific segments and applications within your facility?
– When possible, turn off lights that are not needed or when not needed. Apply IR occupancy sensor based automatic light switches. Apply timer type light turn off switches, where applicable.
– High Efficiency Lamps: Replace existing lamps higher efficiency type. One measure of light efficiency is lumens per watt. Typical payback on such projects ranges from 2 to 4 years, with some rebate incentive from the utility company• Replace Incandescent Lights with Fluorescent Type• Replace Fluorescent lighting with Metal Halide• When possible, replace incandescent, fluorescent, Metal
Halide and mercury lighting with Sodium Vapor lighting.
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$$ Areas of Potential Savings $$:
• Lighting contd:- Opportunities in the Area of Light Fixtures: Could high
bay, transparent, light fixtures be applied with light colored ceiling paint?
– Group Re-lamping: Implement group re-lamping whenever possible. This is one way to maximize and maintain light efficiency/productivity.
– Demand Side Management: Check with the local utility company on availability of Demand Side Management Programs offering incentives for installation of energy efficient lighting systems.
– Lighting Audits: Take advantage of no cost or subsidized lighting audits offered by some utility companies.
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$$ Areas of Potential Savings $$:
• Motor Loads:- Optimize Fan, Blower and Pump Motor Speeds,
application of Fan Laws:- Apply VFD’s, Variable Frequency Drives
- Apply Pulleys
- Turn off motors that idle for significantly long periods of time
– Whenever possible, apply Premium Efficiency Motors
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$$ Areas of Potential Savings $$:
• Compressed Air:- Compressed Air Leak Management:
- Compressed Air Leak Detection Program, using Sound Detection Systems
- Compressed air leaks are expensive. A 1/8” diameter air leak, at 100 psi, can cost more than $2,000 per year.
- Minimize Air Pressure Requirements, whenever feasible. Higher header pressures result in greater air loss and drop in pressure. The 1/8” air leak stated above would cost only $1,300 per year at 50 psi.
- Evaluate the Types of Air Compressors Available. Cleanest or driest compressed air costs more.
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$$ Areas of Potential Savings $$:
• Temperature Optimization: Select a temperature set point such that human comfort and process requirements are met without causing high differential between indoor and outdoor temperatures.
• Air Flow Optimization: Minimize air flow whenever possible. This can be accomplished a follows:
1. Changing fan pulleys
2. Reducing the fan speed through the use of VFD’s, Variable Frequency Drives.
Basic Fan Laws:– Volume, or Air Flow Rate, is directly proportional to the speed of a fan:
• CFM2 = CFM1 (RPM2/RPM1)
– Pressure is directly proportional to the square of speed of a fan:• P2 = P1 (RPM2/RPM1)2
– Motor Horsepower is directly proportional to the cube of the speed of a fan:• HP2 = HP1 (RPM2/RPM1)3
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$$ Areas of Potential Savings $$:
• Operate on Outside Air: Switch the air handling system to outside air when outside temperature and dew point are in the range desired for indoor comfort and process requirements.
– When possible, install air or electric actuator operated dampers to control all air flow.
• Common Chilled Water Systems: – Take advantage of common chilled water headers. Schedule and optimize
operation of the chillers whenever possible. – Monitor chiller usage and loading. Look for the CW bypass valves that stay
open most of the time.
– Annual operating (energy) cost of 1000 ton chiller is in excess of $250,000 per year, or $270/ton/year.
• Application of VFD’s on the following equipment:– Supply and return pumps– Fans and blowers
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$$ Areas of Potential Savings $$:
• Boilers and Steam:- Are your boilers high efficiency?- Are the boiler burners high efficiency?- Is the insulation in a good state of repair?- Is the Steam temperature optimized?- Are the Steam Lines well insulated?- Use smaller, local, boilers to serve remote loads
instead of running a long header to a remote load. - Establish a steam trap maintenance and steam leak
detection program.- Cogeneration: Can lower pressure, return steam be
used for generating electric power?
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$$ Areas of Potential Savings $$:
• Stack Heat Recovery:- Is there a significant amount of heat
wasted/exhausted from your furnace and oven stacks?
- Investigate heat recovery potential at the stacks
- Studies can, sometimes, be funded through DSM programs.
- Possible applications for waste heat:- Hot Water
- Steam
- Space heat or HVAC
- Batch Preheat
- Combustion Air Preheat
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Financial Justification for Energy Conservation Project
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NOTE: This is a simplified version of customary financial analysis conducted for development of Project Justification. - Assume that the Investment or Project is Commissioned into Service at the Beginning of Year 1
1. Annual Utilities Cost, @ Assumed Annual Discount $0.05/KWH; 24/7Operation (Interest) Rate: 10%on Equipment to be Replaced (130,699)$
Initial Cost of Project: Proj./Eq. Life Operating Years & Cash Flows200,000$ 10
Year 2nd 3rd 4th 5th 6th 7th 8th 9th 10thDescription: 1 2 3 4 5 6 7 8 9 10
COSTS:
Write-off of Existing Investme (20,000)$ @ Book Value
2. Depreciation Cost (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$ (20,000)$
3. Taxes @: 0.65% (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$ (1,300)$
SAVINGS:
1. Utilities / Energy: 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ 78,420$ Eff. Improvement. 60%
2. Utility Company Rebate: 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 13,070$ 10%
3. Est. Annual Maint. Cost 4,000$ 4,000$ 4,000$ 4,000$ 4,000$ 3,000$ 3,000$ 3,000$ 3,000$ 3,000$ Reduction:
4. Reduced Safety Incident -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ Rate:
Net Annual Cash Flows: 54,189$ 74,189$ 74,189$ 74,189$ 74,189$ 73,189$ 73,189$ 73,189$ 73,189$ 73,189$
FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEnergy Conservation Project Example
Financial Justification for Energy Conservation Project
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Year 2nd 3rd 4th 5th 6th 7th 8th 9th 10thDescription: 1 2 3 4 5 6 7 8 9 10
Net Annual Cash Flows: 54,189$ 74,189$ 74,189$ 74,189$ 74,189$ 73,189$ 73,189$ 73,189$ 73,189$ 73,189$
PV's, Present Values: $49,263 $61,314 $55,740 $50,672 $46,066 $41,314 $37,558 $34,143 $31,039 $28,218
NPV (1) $435,326 Sum of ALL Present Values from the ten Year Life of the Equipment or Project
NPV (2) $435,326 Excel Based Calculation
IRR 36% Average of ALL Cash Flows, or Net Savings Generated By the Project, During its Ten Year Life Expectancy Divided by the Total Investment
ROI: 37% Net Inc./Avg.Total Assets:
Payback Period, in YEARS: 2.72 Total Investment Divided By the Average of Cash Flows
FINANCIAL ANALYSIS OF CAPITAL INVESTMENTSEnergy Conservation Project Example
Metering Integration
• Products:–TRIDIUM–Orchestrator/Giallarhorn–Dialup Recorders/Stark RT–Veris/–PML–Square D–GE–Schlumberger–AEM/Engage
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Services:Data AcquisitionDatabase/Historical DataPower Bill GenerationAd Hoc ReportingLoad ForecastingReal Time PricingWeather DataDemand ControlDepartmental Accounting
Metering from Utility down…
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Cost Center Allocation
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Load Forecast
Square D Power Logic
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GE Power Leader
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Substation Reporting
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Web Based SCADA and Reporting
• Products:– TRIDIUM– Orchestrator/Giallarh
orn– JAVA Messaging
Software
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Services:Data AcquisitionHistorical Data CollectionLoad VerificationCustom Reports Network DesignShared Savings Accounting
Web Based Architecture
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LonMark Devices
JACE-NP
Router
BACnet Systems
Ethernet LAN
HubWorkstation
Pager or PDA
Multi Site Web Based System
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Pager or PDA
JACE-NP
Hub
Web Browser
Router
JACE-NP
HubRouter
Web Browser
Web Supervisor
JACE-NP
HubRouter
Load Summaries
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Performance Profiling
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Power Bill Calculation
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• Process HVAC Controls Including:– 2000 Point DDC System with 12+ Operator Stations
Operating on plant Ethernet Network– Historical Data on plant network. Info shipped with
product– Air Washer Control with Economizer Energy Control
and Dewpoint Process Control strategies– Chiller Control with Primary/Secondary Pumping
Systems– BACNet interface to TRANE Chillers– Overall Investment by PPG: $4-5 MM (includes
mechanical modifications)
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Process HVAC Control Systems Example
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EMS CW System Monitoring Screen
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EMS Chiller Performance Monitoring Screen
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Air Washer
• Customer Data Center & 990 Datacenters• Integration of Critical support Systems:
– Liebert A/C and UPS– Fike Fire Alarm– MGE/Square D Power Distribution Units– Russelectric Switchgear– Catepillar Generators– Water Detection Systems
• Alarming and Historical Data using Orchestrator and Giallarhorn system
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Marlboro, Mass.
Staples Overview
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Power Distribution Equipment
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Power Usage Analysis
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Generator Monitoring
Report Generation
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Automated Energy Management Systems
• EMS Control Routines– Lighting Control - Schedule the lights in the
facility as required. Include tenant override from switches or phone.
• Intelligent Breaker Panels communicate w/EMS
– Demand Limiting - Temporarily shedding electrical load to prevent a demand peak being set for monthly electric utility billing.
• Need a thorough understanding of utility rate structure
• Real time pricing complicates issue
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Automated Energy Management Systems
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Automated Energy Management Systems
Automated Energy Management Systems
• EMS Control Routines– Duty Cycling - Shutting down equipment for
predetermined short periods to save KWh during operating hours.
• Not used much anymore due to equipment failures
– Load Forecasting - Utilizing the utility data, occupancy data (production data), and weather data to predict peak usage pattern. Allows forecast to be generated for several days at a time.
• Deregulated power buying
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Automated Energy Management Systems
• The future– Web technology
• Starting to be integrated
• Graphics in controller or HVAC equipment
• Browser interface (Internet Explorer 5.0)
• Internet/intranet connectivity
• Connect to any PC with Internet Explorer with proper security access
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Automated Energy Management Systems
• The future– Web technology integrated tightly
• Run your facility from anywhere in the world
– Control routines become smarter• Adaptive intelligence will be commonplace
– Costs remain constant or fall slightly• Capabilities will increase as computers become more
powerful and programmers create better tools.
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