adopting green technologies th h f st i l st lthrough use

Adopting Green Technologies th h f St i l St lthrough use of Stainless Steel

Pravin GoelCII – Green Manufacturing Summit

New DelhiMarch 17-18, 2011

1GII – Green Manufacturing Summit, New Delhi March 17-18, 2011

What is Stainless Steel?

• Stainless Steel is an Alloy of Iron with minimum 10.5 %Iron with minimum 10.5 % Chromium

• Chromium forms a layer ofStainless

Passive CrO Film

• Chromium forms a layer of Oxide which is

Very Thin

Steel

– Very Thin– Passive

I i

Rust

– Impervious– Self Forming instantly on damage

Steel / GI


Important Properties


Stainless Steel Properties

• AestheticsI h tl C i

• High CleanabilityE il ld bl• Inherently Corrosion

ResistantH i i

• Easily weld-able• Excellent impact

i t• Hygienic• Versatile

Hi h t th t

resistance • High temperature

resistance• High strength to weight ratio E ll t f b i ti

resistance • Fire resistance

C i ti• Excellent fabrication properties

• Cryogenic properties • Environment friendly


High Resistance to Corrosion

• Suitable even for environmentsenvironments like coastal area.

Extremely SevereSevereSevereModerateMildNegligibleCorrosion map of India


Corrosion map of India

Fire ResistanceHigh Strength at High Temperature

Mi i t t l d f tiMinimum structural deformation

Retains half the room temperature strength at 500°Ctemperature strength at 500 C

No painting required, not prone to fire

6GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Fire testing: Darchem Engineering, NiDI

Stainless Steel Applications in Building and ArchitectureBuilding and Architecture


Chrysler Building, New York

The Art deco Top wasThe Art deco Top was clad with SS in 1930

Still looks gleaming inStill looks gleaming in marine, urban and industrial environment even after 75 years

Manually cleaned only y ytwice since installation


Largest Gold LEED Certified Building: Pittsburgh Convention Centerg

Bare St i lStainless Steel Roof

9

Reducing Energy Requirements

Phoenix City Hall

• Perforated, polished stainless steel window shades

• US$285,000 one-time capital savings

• US$200,000 annual air conditioning sa ings

10

savings

Ronald Reagan Washington Airport Terminal Roof

Completed 1997

• Type 304, 0.559 mm thick• 54 small Bermuda domes 13 m x 13 m


• Dull finish• Batten Seam landside canopy

Pittsburgh International AirportPittsburgh International Airport Roof

• Airy concourse with 80ft radius Barrel roof• Terne-coated (Tin/ Zinc) finish to impart color• 316 grade SS


g• Completed in 1992

Source : SS architectural facts

Petronas TowersKuala Lumpur, Malaysia

Cesar Pelli & Assoc.

Stainless: Type 316Stainless: Type 316Height: 88 stories1,483 feet (452 m)

Flat panels:0.098 in., (2.5 mm),Cambric finishCambric finish

Tubular panels:0.118 in. (3.0 mm), No 4 polishNo. 4 polish

13

Railway station roofing

• Resin-coated profiled SS roof (10,000 sqm) • Koperkhairane railway station, Navi Mumbai • 60 years life guarantee


60 years life guarantee• Two more stations also clad in SS

Modular Operation Theatre/ Doors

OT/ Fire DoorsS SStainless Steel Walls and equipment


Source: http://www.cleanroomindiabase.com/products.htm#cr

Modular Kitchens in SS


Station Infrastructure

Turnstiles, DMRC

Turnstiles, DMRC


Dividers, DMRCWaterloo Station, London

Wear Resistance PropertiesSugar Cane CarriersSinimbu Mill – Brazil – 2004

g

Stainless 410D Original = 6,35 mm

3 harvest seasons = 5,98 mmCarbon Steel A36 Original = 9,50 mm

3 harvest seasons = 5,50 mm

• Much higher loss in thickness for carbon steel• Carbon steel with intensive scratch presence due to wear caused by sand in

the processSt i l 410D k it f i t t


• Stainless 410D keeps its surface intact

Important Green Properties

• Aesthetics – No need of Painting VOC reduction

• Hygiene Reduction in pre treatment of food/water• Hygiene – Reduction in pre-treatment of food/water

• High Clean ability – minimum use of water resources

• High Strength to Weight Ratio – Lightweight structures, saves energy (e.g. Railway Wagons)

L M i t F Lif• Long Maintenance Free Life – Less need of Replacement.

• Recyclable 70% f SS i d f l d• Recyclable – 70% of SS is made from recycled scrap. Reduces Waste Stream. Saves Renewable Resources.


Recycling

• Stainless Steel Recycling is not a theoretical jargon.j g

• It is a self sustaining process• The alloying elements –y g

Nickel, Moly, Chrome and Iron are expensive and it is

Scrap

economically cheaper to recycle.M th 70% f St i l• More than 70% of Stainless steel is made from recycled scrap


scrapRe-meltingSource: Euro-inox report on Recycling of Stainless Steel

No Degradation

• Stainless Steel is not consumed, it remains part of the sustainable closed loop systems.part of the sustainable closed loop systems.

• Unlike many other engineering materials, SS is recycled without any degradationSS is recycled without any degradation.


Source: Euro-inox report on Recycling of Stainless Steel

Green Material – LEED CertificationRecycled Content >60- 70%Is it 100% Recyclable YesDoes it Provide Long life Yes (reduces maintenance and disposal frequency)g ( p q y)Is construction waste diverted from landfill

Yes (high scrap value and potential to reuse)

Can it be salvaged and YesCa be sa aged a dreused during renovation

es

Is it a low emitting material Yes (no coating= zero emission)Can it help improve indoor Yes (no VOC corrosion resistant bacteria removal)Can it help improve indoor air quality

Yes (no VOC, corrosion resistant, bacteria removal)

Does it help avoid use of toxic material

Yes – long lasting termite barriers, minimal roof runoff

Can it save energy Yes (sunscreens, roofing)Can it conserve water Yes (corrosion and earthquake resistant water lines)Can it extend life of other Yes (stone and masonry anchors fasteners etc)


Can it extend life of othermaterial

Yes (stone and masonry anchors, fasteners, etc)

Source : As reported in ISSF in 2002

Stainless Steel in Water applicationsapplications


Stainless Steel in Water Applications• Antibacterial and Hygienic: Recommended for Food

products• Handling of drinking water: Does not change the taste of

the water• Low Surface roughness (only 0 15 to 0 25 μm)• Low Surface roughness (only 0.15 to 0.25 μm)

– Reduces deposits and film formation– Surfaces are smooth, hard and homogenous. – difficult for Bacteria and Fungi to adhere. – deposits are minimal.

• Stainless Steel is not affected by vandalism and graffiti.Stainless Steel is not affected by vandalism and graffiti.• Wear resistant:

– Remarkable for its abrasion and erosion resistance.


Source: EuroInox: The stainless steel lining of drinking water reservoirs –Initial erection and refurbishment

Global References

Taipei Financial Center Petronas Towers, Malaysia Aurora Residential Towers, Australia

304 grade SS Press Fitting type piping To accommodate High Pressures and Vibration. Fire protection H t d C ld W t S l


Hot and Cold Water SupplySource: High pressure Urban water Distribution Nickel Vol20, number 2, March 2005

Extending building life to 200 years

• A new Concept for Japanese High Rises

• An ‘all-stainless-steel’ piping system aims to extend the life of residentialextend the life of residential high-rises.

According to the report titled 200 YearsAccording to the report titled 200 Years Housing Vision, the average apartment building in Japan lasts only 30 years, compared with 55 years for American homes and 77 for English ones The short lifespan isand 77 for English ones. The short lifespan is an economic burden for residents as well as a hindrance to conservation efforts.

26GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Source: www.nickelmagazine.org/apartments

Global References

• Lightweight bridges are used to carry potable water and pedestrians across river spanspedestrians across river spans up to 632 m in Japan

• 85% Type 304• 10% Type 31610% Type 316• Some 2205 near the coast

• No repainting• 40% cheaper over 30 years

Lightweight Bridge to carry drinking water in Tokyo.

p y• First one built: 1983• Max pipe diameter: 0.8 m• There are now ~3000 such

bridges in Japan

27GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Source: Peter Cutler, NiDI, JSSA, Nickel Magazine Mar2005

Mettur Dam, Tamil Nadu

• Raw water handing in Mettur Dam, Cauvery RiverFi t t i l t l t i i• First stainless steel raw water pipe in India (1998)

• Lightweight meant easy installation in hill thilly country

• >50 year life expected (2 replace-ments of cast iron in that time)

• Smooth bore meant sustained low pumping costs

• LCC analysis: 60% saving over 50 years

28GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Source: Peter Cutler, NiDI

Salt Spray Test Comparison

In Salt spray Test Chloride concentration specified (3%)is hundred times moreIn Salt spray Test Chloride concentration specified (3%)is hundred times more than in drinking water (0.025%) and even more than in Sea Water (1.8%)


Source: Salt Spray Test and its use in ranking stainless steel- ISSF, May 2008

Applications in HospitalsAs per "Scottish Health Technical Memorandum 04-01:"11.8 The materials generally used for the conveyance of water in healthcare premises are stainless steel or plastics. Copper is only used in exceptional circumstances such as, an extension to existing premises with short life expectancy, or very small stand alone premises.alone premises.

Erosion in Copper Pipes


System can be pressure tested up to 25 BarSource: Bright Future for SS Plumbing, Association of Plumbing and Heating contractors

Effect of water velocity on corrosion rate

Copper0.018

Copper

(mpy

)

0.012

0.015

Mild steelsion

rate

0.012

0.009

Stainless steel

Cor

ros

0.003

0.006

Stainless steel

Fl (f / )0 4 8 12 16 20

0 32 28 24


Flow rate (ft/sec)

1522

Differences between traditional materials and stainless steels in potable water

Steel, ironcopper alloys Stainless steelpp y

Water contamination Fe, Cu, Pb, Zn

Almost nil after system t bilicontamination stabilises

Velocity < 2 m/sec Up to 40 m/sec

Water chemistry LimitedUnlimited within range of potable

waterswaters

Durability 20 – 40 years 100 years


Demolition wasteDuring operationDuring construction


Durability Tests in Japan


Why Fire Sprinklers Fail?

Newly constructed HDIL Building on fire18th Nov, 2010

3 persons Killed


3 persons KilledFire in “Bombay House” Tata group HQsFeb 09, 2011,

Application in Fire Fighting Systems


Approvals to use stainless steels

• National approvals in EU Member States will be replaced by European Acceptance Schemebe replaced by European Acceptance Scheme

• USA:ifi d d d f bli t l– specified grades approved for public water supply

without restriction under ANSI/NSF 61– approved under International Building Code– approved under International Building Code– approved under International Residential Code

• National approvals in Australia/New Zealand• National approvals in Australia/New Zealand, China, Malaysia

• India


• India .....

Plumbing Code – India

• 2008 Uniform Plumbing Code – India– Page No 119 Clause 605 11Page No. 119, Clause 605.11– Galvanised Iron:

W t Pi & Fitti d f l i d• Water Pipes & Fittings made of galvanisediron shall not be recommended in piping systems used to convey potable watersystems used to convey potable water


SS Press Fit Product

• Pipe – SS Grade (AISI 304 grade)• Fittings Innovative Press Fit Design (AISI• Fittings – Innovative Press Fit Design (AISI

304 grade)Sealing Ring– Sealing Ring :CIIR/EPDM

P fitti T l• Press fitting Tools– Manual / Hydraulic– Battery Operated


Stainless Steel Plumbing System


Press Fitting Installation

InstallationInstallationFast, Clean & Safe

Pipe Cutter Manual Pressing Tool No Soldering, No WeldingNo Screwing

After Pressing


After Pressing

SS Plumbing

• No general corrosion so no need for corrosion allowance

• No Threading required, hence thinner – 1/3rd the weight of GI pipe

• No need for protective coating• No need to control water chemistry- suitable for y

both Soft as well as Hard Waters• Water purity is maintained• Lightweight• Easy to Install


y• Equipment is durable with Low Life Cycle Cost

Waste water treatment - LCCHuddersfield, UK

Waste water treatment

← Old

Waste water treatment

• 98% reduction in N maintenance costs

• 25% extra plant

New ↓

% pcapacity

43

Easy to install

Easy to use in Difficult areas

Indus Hotel, Delhi Flat in Mumbai

Easy to use in Difficult areas

Time taken : About 8 hrs against 2-3 days for GI& Copper (1/3rd time). E t d t d f th t 4 5 h


Expected to come down further to 4-5 hrs.

Photographs of Installations

Gwalior – Heritage HotelAIIMS Expansion Mumbai - Flat

Delhi House Hotel Delhi


Commercial - BakeryDelhi - House Hotel - Delhi

A Big Builder, Mumbai


Life Cycle Costs

Cost GI SS• Total Cost 8,000 14,000• Average Life 10 years 50 years

– Repairs 1 times Nil

Cost of Repair (5 times) 10 000 0• Cost of Repair (5 times) 10,000 0– Replacement 4 times Nil

• Cost of Replacement 60,000 0p ,• Cost of Interiors 60,000 0• Total Lifecycle Costs 138,000 14,000


Life Cycle Cost(whole of life cost)

Initial Installed Costs• Materials • Fabrication • Installation

+• Materials • Fabrication • Installation

Costs over the life of the structureM i t R l t Di ti• Maintenance • Replacement • Disruption


The 1:10:100 Rule• Cost incurred at various stages

Cost of Design Change

1

Cost during Repair10

Cost due to Failure/ Accidents

100


Summary ComparisonParameter GI PPR cPVC Copper SS RemarksCorrosion Resistance * 5* 5* **** 5* 304 Grade SSH i * *** *** **** 5*Hygiene * *** *** **** 5* Recommended for Food and Pharma equipmentMaintenance Free Life * *** ** *** 5* No need of replacementEnhances Building Life * *** *** **** 5* No leakage, hence no damage to buildingStrength of Pipes **** ** * *** 5* SS is the strongest MaterialEase of Installation ** ** *** ** 5* Fast installation with Low Skill workerEarthquake Proof *** ** ** *** 5* Withstands the vibrations and shocks due to its ductile natureCleanability * ** ** **** 5* No deposit buildup due to smooth surfaceFood Grade * ** ** **** 5* Meets all food grade standardsHigh temperature Application *** * * **** 5* Retains strength at high temperatureLow Temperature Application *** * * *** 5* Is not brittle at low temperature, unlike plastics or GIFire Resistant **** * * *** 5* Withstands High temperature.Experience of Usage 5* * * 5* 5* Worldwide usage experinence of 30‐40 yearsOutside Painting Required * **** **** **** 5* No need of paintingDeposition of Algae ** * * *** 5* Smooth surface prevents algae buildupBlockage Problem * ** ** **** 5* No deposit buildup hence no blockageDamage due to Drilling **** ** * **** 5* Strongest material doesn't get damaged due to drillingHigh Flow Rate of Water ** *** *** *** 5* Smooth and Wear resistant at High Flow rateLow Roughness (less scaling) * *** *** **** 5* Smooth surface prevents depositionp pUsage in Public Building * * * ** 5* Strong material not easily damagedWear Resistant * * * * 5* Not effected by sand or high flow rateJoint Assurance System *** * * ** 5* No Welding or Solution joining. Permanent Mechanical JointSaves Pumping Energy * *** *** **** 5* Smooth surface need less electricityWater Quality affect * **** **** **** 5* No change in water quality during storagePressure Rating *** ** * *** 5* Highest pressure rating of 25 barg Highest pressure rating of 5 barJoint Strength ** * * ** 5* Press fit joint has foolproof and high strength jointApplication Range *** ** ** **** 5* Used for Air, Water and Many GasesLess conduiting (Jhiri) reqmt ** * * *** 5* As Pipe dia is lessHigh Wall Strength *** * * *** 5* Less Brick cutting for piping retains its strengthSaving in Labor Cost * **** **** ** 5* Fast installation with Low Skill workerSaving in Installation Time * *** *** ** 5* Fast to install (approx 1/3rd time of GI piping)


Saving in Installation Time 5 Fast to install (approx 1/3rd time of GI piping)Application in High Rise Buildings *** ** ** **** 5* Not affected by Vibration and MaintenanceCost *** 5* 5* * ** Slightly more than GI and othersLow Diameter possible * * * **** 5* High flow rates allow for use of low diameterLife Cycle cost * *** *** **** 5* Lowest lifecycle costTotal 5 * 1 2 2 1 34 Highest Rating in most parameters

Scale : 1 Poor, 5- Best

Some Major Clients

• Chennai Airport• Kanshi Ram Hospital, Noida

• DLF- Magnolia, Golf Course, Gurgaona s a osp ta , o da

• Indus Hotel, Sahadhara• AIIMS, Delhi• Sugdha Hospital Hisar

• Jindal Guest House, Delhi• Sony Bakery, Delhi• Orbit Flat Mumbai• Sugdha Hospital, Hisar

• Jindal Hospital, Hisar• Govind Nursing Home, Hisar

Orbit Flat, Mumbai• Jalandhar• Chandigarh

P hk l• Heritage Hotel, Gwalior• Houses – Punjabi Bagh,

Pitampura,

• Panchkula• Ambala• Haveli, Jalandhar

• Farm Houses, Delhi • Pranayam Floors, Gurgaon


To ConcludeTwo Piers, Progreso, Mexico

• Functioning pier1941,

Stainless Steel barsFunctioning pier

– Built about 70 years ago (1937 1941)(1937-1941)

– Stainless rebar

• Non-functioning 1967, Carbon

Steel barsg

pier– Built about 35 years

agoago– Carbon steel rebar

Photo courtesy of the Nickel Institute


For more details please contactPRAVIN GOELPRAVIN GOEL

+91 98107 06415JSL Stainless LimitedJSL Stainless Limited

[email protected]@hotmail.com

BLOG: stainlesssystems.blogspot.com

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