analysis of the ventilation system - universiteit...

Analysis of the ventilation system

Internship report External supervisor: R.F.J. Leurink

Jasper Zuurveld (s1479660) Engineering department

University of Twente UT supervisor: S. Hoekstra

Grolsch brewery, Enschede

1 March – 31 May 2018

Analysis of the ventilation system – Jasper Zuurveld II

Preface I would like to thank Grolsch for the possibility to execute my internship at the brewery. It was a great

experience to be able to walk through the different areas of the brewery in order to get to all air

treatment units. Also the possibility to join the “bier ambassadeurs programma” is really appreciated.

Furthermore I would like to thank the Engineering team at Grolsch for the good time during my

internship. The team was very open to each other and there was always time for some questions. As an

engineering team can be imagined, there was a lot of coffee and a good amount of sarcasm involved,

providing a pleasant atmosphere. Thereby I would like to thank Rob Leurink for his time, effort and

expertise while supervising me during the internship. He gave me a great insight in the way he is

working and how it is to be working in a technical environment.

The last person I would like to thank is Eric. Eric has been my eyes and ears, in and around the

ventilation units. He is the one who is responsible for the maintenance concerning the ventilation

system of the brewery, resulting in a lot of knowledge of the system. Therefor he was a great help when

I had questions about the ventilation units.

Analysis of the ventilation system – Jasper Zuurveld III

Summary This report contains the main findings of the 3 month internship of Jasper Zuurveld, which started 1

March 2018. The assignment for this internship was to investigate the state of the ventilation system at

the brewery. The ventilation system was installed around 2003, during the build of the brewery. The

goal of the internship is to investigate the current state of the ventilation system. This investigation is

divided into the following parts:

• Update the documentation of the ventilation system

• Determine the criticalities and risks of the system

• Investigate the maintenance performed and improve the maintenance plan if needed

• Analyze the controls of the system and provide recommendations to improve those controls.

The documentation of the ventilation system is updated and supplemented, with maps and tables to

provide more insight in the different ventilation units. These files can be accessed digitally, ensuring that

everyone can access them easily.

In order to find the risks and criticalities of the ventilation system a QFMECA is performed. Out of the

QFMECA came that Grolsch has the most risks on a shortage of refreshment of the air and on controlling

the relative humidity.

The first one is important because the government has made certain rules that there should always be

enough refreshment. In offices there is the possibility to open the windows and at packaging the roof

hatches can be opened, meaning that fresh air still could enter the building. For the main lab and the

visitors are this is not the case, so these ventilation units have more priority.

The second risk taken is on the relative humidity which is present in multiple areas and has on average

the highest risk priority numbers. The main reason for this is that the relative humidity is not controlled

in most areas. Also there are almost no opportunities to influence the relative humidity, because the

weather outside has the most influence on it. The result is that during the winter, when the outside air is

relative dry, the relative humidity in the brewery is also way too low. To lower the risks taken on

humidity, the humidity should be monitored at the offices and visitors area.

At the moment there is not a really strong maintenance strategy for the maintenance of the ventilation

system. One worker of the technical service is responsible for maintaining the air treatment units. He

has on average 3 days a week in which he should maintain the ventilation system. This includes also the

heat piping towards the ventilation unit, electrical and mechanical matters and problem solving. An

improved maintenance plan is generated in collaboration with the mechanic who is responsible for the

system. In this way, the system will be maintained properly and the chance of breakdowns will decrease.

At the Grolsch brewery, the ventilation system is controlled based on the outside temperature. Based on

the outside temperature the temperature of the ingoing air will be calculated. At packaging the system

is also controlled on the inside relative humidity. For the controls multiple recommendations are

provided to improve the working of the system.

Overall a lot of recommendations are provided in a recommendations report. These recommendations

are prioritized and provided with an indication of the amount of time and/or cost is takes to implement

the improvement. All the files generated for the analysis are provided to Grolsch digitally.

Analysis of the ventilation system – Jasper Zuurveld IV

Table of content

Preface .......................................................................................................................................................... II

Summary ...................................................................................................................................................... III

Table of content ........................................................................................................................................... IV

Table of figures ............................................................................................................................................. V

1 About Grolsch ....................................................................................................................................... 6

2 Introduction .......................................................................................................................................... 7

2.1 Why should there be ventilation? ................................................................................................ 7

2.2 Possibilities of ventilation ............................................................................................................. 7

3 Problem definition .............................................................................................................................. 10

4 Situation at Grolsch ............................................................................................................................. 11

4.1 Layout of Grolsch ........................................................................................................................ 11

4.2 Overview of the air treatment units ........................................................................................... 12

4.3 Locations of the air treatment units ........................................................................................... 13

5 Risk analysis ........................................................................................................................................ 15

5.1 QFMECA ...................................................................................................................................... 15

5.1.1 Results of QFMECA ............................................................................................................. 16

5.1.2 Risks at Grolsch ................................................................................................................... 17

6 Maintenance ....................................................................................................................................... 18

6.1 Current maintenance at Grolsch ................................................................................................. 18

6.2 Deferred maintenance ................................................................................................................ 18

6.3 Improvements on maintenance .................................................................................................. 19

7 Controls of the ventilation system ...................................................................................................... 19

7.1 Expected pattern during the year ............................................................................................... 20

7.2 Working principle at Grolsch ...................................................................................................... 20

7.3 Improvements on controlling the system ................................................................................... 22

8 External parties ................................................................................................................................... 24

9 Conclusions ......................................................................................................................................... 25

10 Recommendations .......................................................................................................................... 26

11 References ...................................................................................................................................... 28

12 Appendix ......................................................................................................................................... 29

12.1 Appendix 1: Milestone planning ................................................................................................. 29

12.2 Appendix 2: Overview of the components in the air treatment units ........................................ 30

Analysis of the ventilation system – Jasper Zuurveld V

12.3 Appendix 3: Inside of a ventilation unit ...................................................................................... 31

12.4 Appendix 4: Overview of the components in the air dryers ....................................................... 34

12.5 Appendix 5: QFMECA .................................................................................................................. 35

12.6 Appendix 6: Photo report (In Dutch) .......................................................................................... 36

12.7 Appendix 7: Overview with recommendations (In Dutch) ......................................................... 46

12.8 Appendix 8: Self-reflection on the internship at Grolsch ........................................................... 48

Table of figures

Figure 1: Types of ventilation systems .......................................................................................................... 8

Figure 2: Project chart ................................................................................................................................. 10

Figure 3: Map with the different areas at the Grolsch brewery ................................................................. 11

Figure 4: Cover of ring binder with information about the air treatment units ......................................... 12

Figure 5: Location of the air treatment units .............................................................................................. 13

Figure 6: Floor plan with the locations and some information of the air treatment units ........................ 14

Figure 7: Location of the air dryers ............................................................................................................. 14

Figure 8: Heating and cooling principle ...................................................................................................... 20

Figure 9: Set points blow-in temperature based on outside temperature ................................................ 21

Figure 10:Control parameters ventilation packaging ................................................................................. 21

Figure 11: Weathered outside thermometer ............................................................................................. 22

Figure 12: Roof hoods in front of inlet ........................................................................................................ 22

Analysis of the ventilation system – Jasper Zuurveld 6

1 About Grolsch History of Grolsch In 1615 Willem Neerfeldt founded a brewery in the village of Grolle, which has now become Groenlo, in the Dutch province of Gelderland. His daughter married Peter Cuijper, who was appointed Guild Master of the brewers' guild of Grolle in 1676. In 1895, this successful brewery, known as 'De Klok', was taken over by their descendants who sold it to Theo de Groen, offspring of another true family of brewers. Meanwhile, in that same year, a number of textile manufacturers, merchants and bankers decided to set up another beer brewery, 'De Enschedesche Bierbrouwerij'. During the First World War ingredients were in short supply, causing the quality of the beer to drop, accompanied by a sharp fall in sales. The management of De Enschedesche Bierbrouwerij therefor decided to sell the business to Theo de Groen. In 1922, De Klok in Groenlo merged with De Enschedesche Bierbrouwerij to become 'De Klok', later renamed 'De Grolsche Bierbrouwerij'. Grolsch's new state-of-the-art brewing facility, located on the border between Enschede and Boekelo, became operational in 2004, replacing the old breweries in Enschede and Groenlo. Grolsch is part of Asahi Europe Ltd. since October 2016. [1] Brewing process Brewing beer is a 100% natural process. What the basic recipe is, of course, remains secret, but Grolsch works with two kinds of hops that gives Grolsch its own taste. Of course, the ingredients are of the highest quality and the brewing process is perfectly checked. Hop Hop provides the aroma and the bitter taste of our beer. It is a climber of which only the flowers of the female hop plant are used for brewing beer. In the past, hop was added to beer as a preservative, but today it is added for taste. Water Beer consists of more than 90% water. Good water is essential for a good quality of beer. During the construction of the new Grolsch brewery in 2004, a seven kilometer long water pipeline was built for the original water sources in the Northern part of Enschede. This is done to use the same water for our beer. Barley Barley is a grain and belongs to the grass family. Germinating barley grains (barley malt) are the main raw material for beer. Not all barley can be used for beer. Brew barley contains many starches and few proteins. You can also use other cereals for brewing beer. For example, wheat is an important ingredient of Weizen beers. Yeast Yeast causes the sugars to be converted into alcohol during the brewing process. Grolsch uses her own yeast because every yeast strain has its own character and greatly influences the taste of the beer. There are two types of yeast in the base: above fermentation and low fermentation. [2] Beers In the brewery in Enschede, in addition to the trusted Grolsch Premium Pilsner, various delicious beers are brewed according to their own recognizable recipe. There are various Grolsch special beers (including Weizen, Cannon, Autumnbok, Springbok), Grolsch 0.0% and the various variants of Grolsch Radler, but also Kornuit, De Klok and several other brands such as Peroni Nastro Azzurro. For these brands, Grolsch provides all distribution, marketing and sales activities for the Dutch market. [3]


2 Introduction This report starts with an introduction on why there should be ventilation and how this could be

accomplished. Then the problem definition will be given, with the motivation for this project. An

overview of the ventilation system at Grolsch is provided next. This includes an overview of the

locations and components of the ventilation units located at Grolsch. The existing data is checked

and the information is updated. While having all the documentation of the system, a failure mode,

effects, and criticality analysis (FMECA) is performed, giving an insight in which ventilation units have

the highest risk priority number (RPN) and should get the most care. In section 6 the maintenance of

the ventilation system is analyzed. This is done in combination with the mechanical worker and with

the previous gained knowledge of the FMECA. Analyzing the controls of the system is done in section

7. This chapter will conclude with recommendation to improve the controls of the ventilation system.

In section 9 and 10, all the chapters will be concluded and the recommendations will be given in the

form of a recommendations report. These recommendations are sorted on priority and on the

investment.

2.1 Why should there be ventilation? Refreshment of the air is needed in all types of buildings, for example houses, commercial buildings

and factories. This refreshment is needed to ensure the air quality in the building. Good quality air

has a relative humidity of 40-60% and contains less than 1100 PPM CO2. The quality of the air will

decrease when there is no ventilation due to for example copiers, paperwork and people. This poor

quality air should be taken out of the building. In order to ensure that there is enough ventilation,

the government have set up some rules concerning ventilation. These rules can be found in article

3.6 of the building decree [4]. This provides a minimum amount of ventilation per person or per

square meter. In this way a minimum amount of fresh air is provided every hour. On the other hand,

the air flow not must not exceed 0.2m/s while entering the area, because this could be irritating for

the people working in the area.

In addition to the rules of the government, some regulations are stated in the Working Conditions

Decree. Article 6.2 provide some rules concerning ventilation. In order to let people work in the

company, the following 4 points must be matched:[5]

1. Sufficient non-polluted air should be present in the workplace.

2. Ventilation installations should always be ready for operation.

3. Ventilation installations should function such that employees are not subjected to

inconvenient draughts.

4. Ventilation installations should be supplied with a control system which detects faults in the

installation insofar as this is necessary for the health of the employees.

According to the points stated above it is a task for Grolsch to make sure that the ventilation system

is working at the moments it should be. Therefor the most common ways of ventilation will now be

discussed.

2.2 Possibilities of ventilation Due to the improvements of the isolation of buildings, the ventilation due to leakage of the building

will decrease. Therefor other possibilities should be used to ensure the air quality inside the building.

The following possibilities are the most common ones that are used to ventilate buildings.


Natural ventilation

This principle uses natural ways to ventilate the building. Natural ventilation can be ensued by

opening a window or a door and by ventilation strips located in windows. This type of ventilation is

very common in residential buildings. This kind of ventilation is called ventilation type A.

Mechanical ventilations

Mechanical ventilation is used when natural ventilation, ventilation type A, is not sufficient or when

the ventilation should be better controlled. Mechanical ventilation uses a ventilator to actively

transport air in and/or out of the building. In this way, the location where the fresh air will move in

and/or the Polluted air will move out can be selected. There are still some options to select when

using mechanical ventilation.

1. Ventilation type B: Only mechanical supply of

fresh air. In this way the pressure in the building

will be increased, resulting in air that moves out

through windows, ventilation strips, doors and

cracks.

2. Ventilation type C: Only mechanical extraction of

polluted air. In this way the fresh air will enter

the building through windows, ventilation strips,

doors and cracks.

3. Ventilation type D: Mechanical supply and

extraction of air. With this option the inside

climate can be controlled the best, because the

ingoing and extracted air can be controlled. By

using an energy retrieval unit the heat of the

outgoing flow is reused to preheat the incoming

flow. In this way a lot of energy can be reused,

meaning less heating costs.

The four different kinds of ventilations systems are visualized in Figure 1. The ventilation at Grolsch is

mostly a type D and sometimes a type B system. This is done to make sure that the air is filtered

before entering the building. When applying system type A or C the polluted outside air will not be

filtered before it enters the building. This will not ensure clean air inside, which should be prevented

when producing consumer beverages.

Possibilities to reuse energy

In general there are three kinds of heat recovery systems namely, a heat recovery wheel, a plate heat

exchanger and a twin coil system. For the first two systems the ingoing and outgoing air should be at

the same location, where the twin coil can transport the heat through another medium from one

location to another. A heat recovery wheel is a turning wheel that is located half in the ingoing and

half in the outgoing air. In the warm flow the wheel will be heated. Because the wheel is turning, the

heated part of the wheel will go into the cold ingoing flow. There the heat will be extracted from the

wheel, preheating the ingoing air. A plate heat exchanger is a simple concept. The ingoing and

outgoing air will transfer the heat to each other while separated by some metal sheets. Unlike with

the heat recovery wheel, there is no mixing possible of ingoing and outgoing air. The last system is

the twin coil system. This system has an air to liquid heat exchanger in the ingoing as well as in the

outgoing air flow. By pumping the liquid, most of the times a combination of water and glycol, the

Figure 1: Types of ventilation systems


heat can be transferred between the two air flows. All of these system will make sure that less

energy will be used to heat the building during the winter.


3 Problem definition Brewing beer is the main goal of the Grolsch brewery. All the processes which have direct impact on

the production of beer have the main focus of the engineering team. But, there are also a lot of

processes that are less connected to the main process of brewing beer, like the ventilation system.

Therefor this system is way less maintained and optimized than the core processes. Most of the time

the ventilation works just fine, but when something is wrong, people notice it directly. Therefor it is a

very interesting subject to investigate and to give recommendations to improve the ventilation

system.

In the first weeks of the internship a project charter and a project planning were generated. Grolsch

has a structured template which is used for all projects. This template produces a one page overview

of the description, goal, results, scope, people involved, risks and benefits of the project. All this

information about the internship project can be found in this overview, displayed in Figure 2. The

combination of this project description and the milestone planning can be found in Appendix 1

Figure 2: Project chart

Risks

Insight in the functioning, risks and maintenance of the ventilation will

be generated. This knowlage will keep the risks, costs, safety and

working climate better in control.

There is a lack of knowledge at Grolsch over the system, which could

lead to wrong information, resulting in wrong conclusions.

Time shortage due to the fact that companies will be consulted and my

contract will end in 3 months.

A - Opdrachtgever

R - Projectleider

I - Inform

S - Support

- Mechanisch Engineer

S - Support

S - Support

C - Consult

I - Inform

- Martin Bosscher

- Freddie Groeneveld

- John Kalma

- Consultant Ext

- Susan Ladrak

- Jasper Zuurveld

- Rob Leurink

Project Description

Goal Result(s) Scope

BenefitsTeam Members Role

An overview of the air treatment system at

Grolsch.

A completed version of a FMECA for the air

treatment system.

A preferred maintenance plan and the

comparison with the existing plan.

The comparison between the system with those

manufactured nowadays.

Overview of possibilities to improve the controls

of the air treatment system.

The total ventilation system of the brewery

will be in the scope of the project.

For packaging the layout of the ventilation

system in the hall will be taken into account.

Depending on the FMECA the focus will

move to the critical parts of the system.

The ventilation system is in use since the construction of the Grolsch brewery in 2002. Since then, maintenance cost is kept to a minimum, not knowing

the effects of that decision. It is not known if the systems produced nowadays significant have improved in comparison to those out of 2002. Controlling

the system is done automatically, but it is not known if these settings are optimized. Also the risks of a system failure is not known.

Investigate the ventilation system to provide

an insight in:

The risks and criticalities.

The required level of maintenance and if it is

currently met.

The difference between the system at

Grolsch and the machines manufactured

nowadays.

Possibilities to improve the control of the

ventilation system.


4 Situation at Grolsch In this chapter the details of the ventilation system at Grolsch will be presented. This includes the

locations and specifications of the 29 air treatment units and the 8 air dryers.

4.1 Layout of Grolsch To be able to distribute the beer to the customers, more than only a beer brewing line is needed. The

brewed beer should be stored in tanks in a refrigerated area and bottled at a packaging facility. Daily

Thousands of tests are done on the beer at the main lab to guarantee the premium quality. Also

manpower is needed in the office like people of HR, sales and engineering. All these different areas

have different requirements on the ventilation system. Therefor the brewery is divided into the

following areas, have all different requirements concerning the ventilation system:

Figure 3: Map with the different areas at the Grolsch brewery

• Brewers home (yellow)

• Packaging (red)

• Offices (orange)

• Visitors areas (green)

• Refrigerated area (blue)

• Main lab (purple)

• Storage (brown)

• Areas without mechanical ventilation (white)


4.2 Overview of the air treatment units In the brewery, 29 air treatment units are installed. In addition to that, there are 8 air dryers that

prevent condensation on the cold beer tanks. The air treatment units can have the following

functions:

• Refreshing of a certain amount of air per hour (m^3/h)

• Heating the air

• Cooling the air

• Humidifying the air

• Drying the air

• Filtering the air

• Reusing the thermal energy that leaves the building

The air treatment units in the different areas have different functions to fulfill. Therefor some

components will be located in one unit, but not in another. In all the air treatment units there is the

possibility to heat and filter the ingoing air. At the offices the air

can be cooled using a top cooling, the same holds for the

refrigerated areas and the main lab. All other areas have no

possibility to cool the air inside the building. Humidifying is

only possible in one warehouse and drying is only done in

the refrigerated areas. The heat or cool energy of the

outgoing flow is reused to pre-heat or cool the ingoing air,

with exception of the air treatment units with a low volume

capacity. A global overview of the air treatment units in the

different areas is given in Table 1. An overview of all the

different components of the 29 different units is provided

in Appendix 2 and a photo report of the different

components of the ventilation units can be found in

Appendix 3. In addition to this overview, there is a ring

binder available that contains additional information of the

29 air treatment units. Including information on

dimensions, powers, efficiencies and materials.

There are also 8 air dryers located in the brewery. The

producer of these dryers is Munters. In the same format

as for the air treatment units, an overview is

constructed with general information of the 8 units. This overview can also be found in Appendix 4.

For the air dryers also, a ring binder is available with some extra information.

Table 1: Global overview of the different components of the air treatment units in the different areas

Figure 4: Cover of ring binder with information about the air treatment units


4.3 Locations of the air treatment units In addition to the overview of the components of the air treatment units, a map is created to indicate

the locations of the units. This map is made interactive. When the pdf file is opened, some

information of the unit will be displayed when moving the mouse towards it. This menu displays the

following information:

• The area that the unit ventilates

• The capacity of the unit in m^3/h

• The type of heat recovery system

• The location Where the unit can be found

This information is displayed in Dutch because some users may not understand English. A screenshot

of this overview can be found in Figure 5. In Figure 6 the same map with the information of one air

treatment unit is shown. In addition to the air treatment units the location of the air dryers are

shown in Figure 7. In this way, the different units can be located rather easily. In combination with

the components overview, the main information of a unit can be gathered rather quickly.

The files mentioned above can be found on the server of Grolsch under the name of: “Gebouw

overzicht met luchtdrogers.pdf” and “Gebouw overzicht met LBK.pdf”.

Figure 5: Location of the air treatment units


Figure 6: Floor plan with the locations and some information of the air treatment units

Figure 7: Location of the air dryers


5 Risk analysis In this chapter the general risk of ventilation will be discussed. In order to get a good view on the

risks taken at Grolsch, a QFMECA is executed together with some colleagues, involving a

maintenance engineer, a brewer and a process engineer. The method and the results of this analysis

will be provided.

5.1 QFMECA To get an overview of the risks and criticalities of the ventilation system, a QFMECA is executed. In

this QFMECA, 5 different areas with ventilation are taken into account. In these different areas

different processes are happening, resulting in other risks. The following 6 areas are taken into

account: the brew house, packaging, offices, visitors areas, cool beer storage and the main lab. For

each area, the effect of the possible failures of the main functions of the system were examined. The

functions are: Cool down or heat up the building, having a certain refreshment of the air in the

building, keeping the humidity in limit and avoiding a certain pollution within the room. For each of

these functions the severity, occurrence and detectability of the failure modes were indexed in a

ranking between 1 and 6. The meaning of this index number is given in the table below. Table 2: Ranking QFMECA

By multiplying these numbers with each other, the risk priority number (RPN) is calculated. When

this number is higher, more risk is involved when this function of the system will fail. Therefor this

function should be secured to prevent a failure from happening. In this case a grading between the

number 1 to 6 is given, therefor the highest RPN possible is 6*6*6=216. Of course this is very unlikely

to happen, because this is an enormous risk. Multiple times a day a failure results in injuries or dead,

without the possibility to detect the failure. Therefor a logic RPN should be chosen to function as

threshold. A threshold is chosen with a medium risk of 3 for all indexes, which will result in a

threshold 3*3*3 = 27. All the RPN numbers were examined if they are above 27. When some

function had an index value of 6, it will always be taken into account.

Functions of the ventilation system The risk of the failure of the ventilation system will be examined during the QFMECA. As discussed in chapter 4.2 the ventilation system has multiple functions to fulfil. The risk of a system that will not work as it should be, could have different consequences in different area. So, the previous mentioned 6 different areas were taken into account. For the QFMECA the components of the ventilation system are converted into the following functions:

• Provide a certain amount of refreshment

• Controlling the temperature


• Controlling the humidity

• Keep pollution out of the inside air

5.1.1 Results of QFMECA In this section, the key findings of this QFMECA will be provided. In table 3 the main risks, when some

ventilation unit or components of it will fail, are given. For example, when the ventilation in the brew

house will fail, the temperature will rise. This will have effect on the people that are in the area, as on

the machines. Therefor more attention should be given to the risk that the ventilation system could

not provide the right temperature. Another interesting one is the relative humidity at packaging,

both a too high as a too low humidity is a risk. The reasoning behind all the generated RPN numbers

can be found in appendix 5.

Table 3: Results of QFMECA

Temperature Refreshment Relative humidity Pollution

Brew house Too high (RPN: 27)

Packaging Too low (RPN: 32) Too high (RPN: 45) Too low (RPN: 40)

Offices Too low (RPN:40) Too low (RPN:64)

Visitors area Too low (RPN:40) Too low (RPN:36)

Refrigerated area Too high (RPN:48)

Main Lab Too high (RPN:45) Too low (RPN:40)

Pollution is in none of the areas a considerable risk. This is due to the fact that Grolsch filters the air

before blown into the building. When applying a ventilation system D the inflow and outflow of air

will be done mechanical, thereby the pollution outside will not move unfiltered into the building.

Also the pollution will not affect the process because the total brewing and bottling process is an

closed process, where the product will not interact with the environmental air.

The one with the highest RPN is the low relative humidity in the offices with a RPN of 64. Therefor

this one will be examined closely. Like stated before, the RPN is a multiplication of the numbers for

the severity, occurrence and detection. The indexes of the relative humidity in the offices were

established by the group on:

• Severity: 4, failure is disadvantageous for the production process.

o A low relative humidity will result in a irritations of the staff. Dry eyes, dry skin and

they will be more thirsty. All of this will result in a lower productivity and more

absenteeism.

o During wintertime the relative dry air will result in a low feeling temperature,

resulting in higher heating costs.

• Occurrence: 4, multiple times a month.

o At the moment there are no inspections, so the group was thinking that this was the

case during the winter months and sometimes in the summer period, resulting in

multiple times a month.

• Detection: 4, will only be noticed during inspection.

o In the offices only the temperature is measured and the relative humidity isn’t. There

is no system to check the relative humidity, so only when there is an inspection, the

low relative humidity will be detected.

With this kind of reasoning the entire QFMECA is filled. In appendix 5 the results of the QFMECA is

given. In this appendix only the ones with a RPN higher than 27 are displayed, because only these are


the interesting ones. The intermediate result of the QFMECA can be found in a separately supplied

Excel file called “QFMECA_ventilation_system.xlsx”.

5.1.2 Risks at Grolsch Out of the QFMECA came that Grolsch have the most risks on a shortage of refreshment of the air

and the on controlling the relative humidity. The first one is important because the government has

made certain rules that there should always be enough refreshment. In case of a failure of the

ventilation system, there is the possibility to open the windows in offices and at packaging the roof

hatches can be opened, meaning that fresh air still could enter the building. For the main lab and the

visitors this is not the case, so these ventilation units have a higher priority.

The risk taken on the relative humidity is in multiple areas present and has on average the highest

risk priority numbers. The main reason for this is that the relative humidity is not controlled in most

areas. Also there are almost no opportunities to influence the relative humidity, because the weather

outside has the most influence on it. The result is that during the winter, when the outside air is

relative dry, the relative humidity in the brewery is also way too low. To lower the risks taken on

humidity, the humidity should be monitored at the offices and visitors area. Also it should be

investigated if the humidity can be controlled by introducing the possibility to control the humidity

in the offices, visitors area and at packaging. This can be done by installing new equipment or by

adjusting the controls. So, when the system fails, controlling the humidity at packaging is the hardest.

During the year, controlling the humidity in the offices and visitors area is the most difficult.

It is important to keep in mind that the control of the system should be examined if this is done

correctly. When illogical actions take place, a lot of energy can be wasted. Also the air quality inside

the building cannot be guaranty. Therefor the logic behind the controls of the ventilation system

should be examined closely. This is done for the ventilation system at Grolsch and the results can be

found in chapter 7.

Also, when the system is controlled as it should be, people can manipulate the system by hand. This

could also result in unwanted effects. A part of the air treatment units are located behind locked

doors, but most units can be accessed by everyone in the brewery. For example some valves for the

heating element were manually opened, resulting in high energy consumption and reduction of

working climate. For the working of the ventilation system, it is best that only the mechanics could

change the settings of the systems at Grolsch.


6 Maintenance This chapter will discuss the maintenance aspects of the ventilation system. First the situation

nowadays at Grolsch will be discussed. Then an maintenance plan will be provided. This plan is

constructed based on visual inspections, maintenance done earlier, advise of producers and the

results of the QFMECA.

6.1 Current maintenance at Grolsch At the moment there is not a really strong maintenance strategy for the maintenance of the

ventilation system. One worker of the technical service is responsible for maintaining the air

treatment units. He has on average 3 days a week in which he should maintain the ventilation

system. This includes the heat piping towards the ventilation unit, electrical and mechanical matters

and problem solving. Because this worker is already working on the ventilation system since the

construction of the brewery, he knows a lot about the system and what the common failures are.

Just after the brewery was build, there was a maintenance plan for the ventilation system. For a

couple of years a checklist was filled to make sure the ventilation system was performing optimally.

The documentation of these years is still available. After a few years, the brewery was taken over by

the SABMiller group and a reorganization happened. There wasn’t time for the ventilation anymore,

because it was not the main process. During this time more failures started to arrive, so the

mechanic got some time back to maintain the ventilation system. Since then the mechanic started to

do the maintenance tasks, but did not fill the checklists anymore. This maintenance consists of

problem solving, cleaning, inspections and small maintenance tasks. Most of the failures will give an

error on the screen in the brewers home. From the point that the mechanic notices this waring, he

will move to the ventilation unit to repair the failure. This can be for example a worn belt, a broken

motor or an air valve that is broken. Because not all failures will give a notification on the screen it is

important that the mechanic occasionally will visually inspect the ventilation units to detect failures.

In addition he will carry out some maintenance tasks like lubricating the bearings.

In addition to the maintenance done internally, some other companies execute maintenance on the

ventilation system. Yearly, the air filters will be delivered and partly replaced by Camfil. During one

week, 2 engineers of Camfil will replace the old filters with new ones and clean the inside of the

ventilation units. The filters are delivered some time ahead, so the engineer at Grolsch can make sure

that the new filters will be at the ventilation units already. He also finishes the replacement of the

filters, because not all of the filters can be replaced during the week Camfil is present. If there is

some budget at the end of the year, another company will be contacted to clean and overhaul one or

two ventilation units. In 2013 the company Blygold was contracted to optimize 2 ventilation units at

packaging.

So, to conclude, at the moment the maintenance that is done consists of: Inspection, problem

solving, conducting of small maintenance tasks, yearly changing the filters and if there is budget

some optimizations.

6.2 Deferred maintenance Because there is not really a maintenance plan the technical service worker executes the

maintenance mostly on his own insight. Resulting in the fact that some maintenance points will not

be executed as many times as they should be. With that reason is for this study there is an inspection

done on the system to see where the maintenance could be improved. To get an insight in this

deferred maintenance, pictures were taken of all the things that are deviating from standard. These


pictures are placed in a photo report. This report contains maintenance actions for the technical

service worker, but also major maintenance actions that should be executed by an external

company. Therefor this photo report will help the team of the engineering department to determine

if there are investment needed to keep the risks low and the system running the coming years. The

photo report can be found in Appendix 6.

Together with the mechanic the bearings of an air treatment unit are inspected. This is done to

investigate the condition and the type of bearing. In the documentation there was no information

about the types of bearings used in the ventilator. Bearings, produced by SKF that are typically used

for this kind of situations, have a lifespan of around 20.000 to 40.000 running hours. Because the

brewery is built in 2003 the expectation was that the bearings would be worn out, but this was not

the case at the unit that was inspected. It turned out during the inspection that standard types of

bearings were used. This was good news, because when a bearing will fail, the bearing can be

replaced rather quick by a new one, namely in 2 hours. Therefor there failure can be resolved rather

quickly. Also this will prevent lots of different spare parts, because the standard bearing are already

on hand.

6.3 Improvements on maintenance For the mechanic at Grolsch an overview is made of all the components that should be inspected

with a specific interval. During the development of this overview, multiple discussions with the

mechanic took place, resulting in a reliable and complete overview. This overview can be used in case

that the current mechanic will stop working at Grolsch for some reason, and must be inputted in the

maintenance management system SAP-PM.

During one of the first weeks of the internship the air filters were changed. This was just before the

beginning of the anther dust season. In this season the air is polluted, this can be seen by for

example the dust on cars. The conclusion, out of a conversation with a specialist on ventilation, was

that it was better change the filters just after this season.

For the ventilation system, time-based maintenance is applied. Once a year the filters will be

changed and the bearings will be lubricated, regardless of the condition. To change based on

calendar time was a conscious choice for changing the filters, because Grolsch is producing

beverages for customers. Another point why changing the filters is not done based on the condition

is due to the fact that there is no digital measurement on the pressure drop over the filters, there are

only analog measurements. The pressure drop over the filter is an indication on the state of the filter,

but does also depends on the volume flow over the filter which is not always the same. This makes it

harder to determine the condition of the filters without digital measurements.

For the other components of the ventilation unit, it is also very difficult to determine the working

hours. This is because the ventilation system is not logged. For some components, like pumps and

ventilators, the working hours can be found in the software, but this number has a maximum of

10.000. After the 10.000 is reached the counter is lowered a little bit, without sending a warning.

Multiple counters have reached this point, so the working hours of these components cannot be

estimated correctly. It is recommended to find a way to save the working hours properly. This can be

done by yearly noting down the values and resetting the counter of the LBK. Another way is to

increase the limit of the counter.

7 Controls of the ventilation system Each ventilation unit at the Grolsch brewery is controlled by a control panels. These panels are

controlling the system based on live measurements. The status of the system and the real time


measurements can be consulted at a computer in the brewers home. The system works autonomous,

but units or components of the units can be switched on or off manually.

7.1 Expected pattern during the year The ventilation system is controlled mainly on the outside temperature. This means that, based on

the outside temperature, the system should heat or cool the air. When it is very cold outside, the

heating element and the heat recovery should be working. When the outside temperature increases,

most of the heating needed can be supplied by the energy recovery, so the heating element will

switch off. The heat recovery will stop when the air supplied should be cooler than the outside

temperature, then the cooling will start. From the point that the extracted air is cooler than the

outside temperature, the heat recovery will turn on. In this way the thermal energy that is already in

the building is optimal used. The logic explained above is graphically displayed in Figure 8 .

Figure 8: Heating and cooling principle

During the internship at Grolsch, a lot all sorts of weather has passed. There were days where it was

freezing outside and days with 28 degrees Celsius. This was very handy with checking if the system

was working like expected, because there was no possibility to look back in time what the system

had done. The conclusion of the evaluation is that the system is doing what was expected, based on

its measurements. The problem however was that not all measurements provided the correct values.

The effect of this will be discussed in the following chapter after the working principle at Grolsch is

explained.

7.2 Working principle at Grolsch At the Grolsch brewery, the ventilation system is controlled based on the outside temperature.

Based on the outside temperature the temperature of the ingoing air will be calculated. For each

ventilation unit the set points for the ingoing air temperature can be adjusted, this can be seen in

Figure 9. The outside temperature is measured on three different places, each one controlling a part

of the ventilation units. During the time that it is cold outside, the ingoing air should be warmed. This

firstly will be done by the heat recovery system. When this is not sufficient, the heating element will

provide the extra heat that is needed. Also, during winter time the air circulation in the offices is

0

1

-10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34

Swit

ched

off

(0

) to

tu

rned

on

(1)

Outside temperature (ᵒC)

Heating and cooling

Heating Cooling Energy recovery


lower than during the rest of the year, this must be done manually. In this way the amount of heat

needed is reduced to a minimum. During the hot summer days, when the temperature of the

outgoing air is less that the outside air, the system will use its heat recovery system as a cool

recovery system. The ingoing air will be cooled by the air that is leaving the building, before the

cooling element cools the air to the required temperature. In this way the amount of cooling energy

is reduced. The air circulation during the summer days is not reduced, due to the fact that the system

has a “top-cooling” and otherwise the cooling is not sufficient and the temperature in the building

would increase.

The program controlling the system is called Desigo Insight. This program visualizes the ventilation

system in a graphical environment. This makes it insightful which processes occur in each ventilation

system. The screenshots of Figure 9 and 10 are also from the same program, which is showing that it

is simple to adjust the set points. When for some reason the program closes and the computer will

shut down the ventilation will keep on running.

Figure 9: Set points blow-in temperature based on outside temperature

At packaging, the system is actively controlling the amount of air circulation, based on the relative

humidity in the building. The process at packaging uses a lot of heat and water and thereby

producing a lot of humidity. Therefor the system is controlled such that with a high relative humidity

there will be more refreshment of the air. The problem is that the system doesn’t reviews the

humidity of the outside temperature. So it can be the case that the outside air contains more

humidity than the inside air and that the ventilation only increases the relative humidity in the

building. The set points for the amount of refreshment can be adjusted in the system, like shown in

Figure 10.

Figure 10:Control parameters ventilation packaging


7.3 Improvements on controlling the system In this section some improvements on controlling the system will be discussed. These improvements

are suggested to get the best out of the ventilation system.

Outside thermometers

During the sunny mornings, the thermometers are located in

the sun. These thermometer have a protection against the

radiation of the sun, but this is weathered like can be seen in

Figure 11. The effect of this is that the measurement of the

outside temperature is much too high. As said before, when

the outside temperature is higher that the temperature of the

air that leaves the building, the heat recovery will start. Due to

the fact that in the morning the measurements shows 6 degree

to high, the colder outside air will be heated up before it will

be cooled. This costs a lot of energy, which could simply be

avoided. Because the system is controlled on the outside

temperature, these temperature meters should be replaced.

Roof hoods at packaging

The ventilation at packaging is done by the

ventilation units and by roof hoods. An

overpressure is created in order to let the air

leave the building through these roof hoods. The

air leaving through these hoods will not pass any

heat recovery system, so the heat is lost. For

some reason a part of the hoods is manually

opened by default when the ventilation is shut

down, also during wintertime. This results in a lot

of heat losses during the winter, so make sure

that these roof hoods are closed by default. This

will also make sure that unfiltered outside air will

not enter the building when the system is off and

there is no overpressure.

Another point is that some of the roof hoods are located just before the inlet of the fresh outside air,

this situation can be seen in Figure 12. This is the case at ventilation units 1.1, 1.2, 1.4, 1.5 and 1.7.

The wet and warm air that leaves through these hoods will enter the building again. The advice is to

close these roof hoods permanently, probably this could be done by some hardware changes.

Minimal running hours

Some Ventilation units are turned off by default. This is due to the fact that the areas are not used

anymore or that other ways of ventilation are applied. For different components of the ventilation

units it is the best when the ventilation unit is turned on regularly. This is for example the case for

Figure 12: Roof hoods in front of inlet

Figure 11: Weathered outside thermometer


components with lubrication. There are 2 ventilation units switched off by default, namely unit

number 4 located at BV2 and unit number 19 located at RB1. It has already happened that a units

broke down when turned on after a long time being turned off, which emphasizes the importance of

regularly switching on the units. For example, an improvement would be to switch on the units on for

half an hour once a week.

Anticipate on weather forecast

When it is a hot summer day, the ventilation system consumes a lot of energy to cool the building

during the day. In the morning the outside temperature is relatively low, providing the possibility to

move the heat out of the building without using the active cooling. At the moment, the temperature

of the ingoing air is determined based on the outside temperature, meaning that the heat will stay in

the building resulting in more cooling cost in the evening. When a weather forecast can be

implemented in the system, the system can cool the building in the morning hours with the outside

temperature when it will be a hot day. Of course the parameters should be defined. An educated

guess for the values is done, when applying more investigation is needed. An example of the

parameters will be:

• Weather forecast of the temperature should be higher than 25 degree Celsius.

• The inside temperature may not come below 21 degree Celsius.

• Ingoing air may not be colder than the minimum provided. Most cases 16 degree Celsius.

• The outside temperature is higher than the calculated temperature of the ingoing air.

Only when all the points above are met the “summer morning program” will be started. When one of

the points is not met the normal program will be followed again.

Relative humidity at the offices

The relative humidity is most of the year too low in the offices, especially during the winter. In the

winter the outside air is already relatively dry and Grolsch has no possibilities to humidify the air. An

additional problem is that at the moment, the relative humidity is not measured in the offices. This

combination makes that the relative humidity cannot be controlled at all. It is important to keep the

relative humidity during the year at 40-60%. The effects of a low relative humidity are not directly

visible, but can be from dry skin and itchy eyes to illness. There are multiple ways to increase the

humidity of the air inside the offices, like for example by placing more plants, place locally some

humidifiers or place a humidifier in the ventilation unit. The best solution depends on the size of the

problem. One colleague has already started an investigation, measuring the humidity in the offices,

so this is an ongoing investigation.


8 External parties During the internship there has been contact between the intern and 2 external companies. These

companies gave a lot of insight in the working principles, do’s and don’ts of ventilation. Blygold in

combination with Agema Advies en techniek and Camfil are the companies that were contacted by

the intern. A short company description and goal if their visit will be given below.

Blygold

“It began in the early 1970’s when Rijk Bleijenberg discovered a new chemical cleaning method for

cooling devices whilst on a working trip in the USA. Later in 1976 he founded his own company under

the name of BlyChem (Bleijenberg Chemicals) and introduced these new innovative methods for the

first time in the Netherlands

In the years to follow, the rising demand for corrosion protection on heat exchangers of HVAC

equipment significantly increased. As a solution a unique new product was ingeniously invented. This

product BlyGold Plus, aptly named because of it’s golden colour, was the launch of the now

acclaimed brand Blygold.

Today Blygold is partnered with more than 75 companies in over 55 countries and is a well-known

and reputable name in the HVAC industry. This is mainly thanks to the dedicated and enthusiastic

partners that have chosen to work with Blygold. Together they benefit from this successful formula.”

[6]

Last year a case study is done to improve the air conditions at packaging during the year. This study

was focused on finding ways to get the temperature and relative humidity at packaging in control.

The solution was a package of which the costs were too high and the rate of return was too low, so

this is not implemented yet. Blygold accepted the invitation to come by and a very informative

conservation followed with their ventilation specialist. This conservation was at the beginning of the

internship, which gave a lot of insight in ventilation and helped a lot executing the internship.

Camfil

“Camfil is a global leader in the air filtration industry with more than half a century of experience in

developing and manufacturing sustainable clean air solutions that protect people, processes and the

environment against harmful airborne particles, gases and emissions. These solutions are used

globally to benefit human health, increase performance and reduce energy consumption in a wide

range of air filtration applications. Our 26 manufacturing plants, six R&D sites, local sales offices and

3,800 employees provide service and support to our customers around the world. Camfil is

headquartered in Stockholm, Sweden. Group sales total more than SEK 6 billion per year.” [7]

Camfil is contracted to replace the air filters once a year, this was done during the internship. On

advice of the engineers of Camfil who were replacing the filters, a study is executed to improve the

performance of the system. Therefor the account manager of Camfil was invited to execute an

optimization for multiple air treatment units. On some locations at the brewery there could be

placed other filters to decrease the costs of purchase and energy cost during the year. On some

locations the best filters were already used. This advice is forwarded to the head of the technical

service, which will order this more efficient filters next year during the filter change.


9 Conclusions The internship assignment was meant to investigate the ventilation system at the Grolsch brewery.

The goal of this assignment was to investigate the ventilation system to provide an insight in:

• The risks and criticalities.

• The required level of maintenance and if it is currently met.

• Possibilities to improve the control of the ventilation system.

In addition to these goals the documentation of the ventilation system should be updated to get

more insight in the system installed. This last one is done by creating maps with the locations of all

the different ventilation units and with the locations of the air dryers. In total the system installed at

Grolsch consists out of 29 ventilation units and 8 air dryers. Information about the components

inside of the ventilation units is collected in one table to provide a quick overview.

Next the risks and criticalities were determined by executing a QFMECA. The conclusion of the

analysis was that each area in the brewery has different requirements on the ventilation, resulting in

different criticalities and failure modes. At the moment the system or components of the system

fails, most trouble will be to keep enough refreshment and to keep the relative humidity on the

correct level. Keeping the relative humidity on the right level is, also when the system doesn’t fails, a

problem because the relative humidity is not measured and controlled in most parts of the brewery.

The maintenance of the ventilation system is done by one mechanic who is involved in the system

since the start of the brewery at this location. Therefor he knows a lot about the system, but this

made him easygoing on some parts that are not that important in his eyes. To make sure all the

points of the ventilation system will be checked and maintained, a maintenance plan is created in

cooperation with the mechanic. The results of the QFMECA were used while creating this

maintenance plan. In addition to this plan a photo report is created, which consist of all the

remarkable points of the ventilation system which should be maintained by the mechanic or by a

project of the engineering department.

The last part in this report goes about the controls of the ventilation system. The most outstanding

conclusion is that the system is controlled on the outside temperature, not on the temperature

measures inside the building. This will not give too many problems in general cases when the

setpoints are properly programmed and the building consist of one open area. But when there are

multiple rooms, like in the offices, the ventilation system cannot perform optimally. Also some

improvements on the controls are provided of which some are applied already. These improvements

will decrease the energy usage or increase the inside air conditions.

During the investigation a lot of points of attention passed. This means that there were a lot of things

that could be improved or optimized. These recommendations are collected and summarized in a

recommendation report. This report is divided into 3 priorities to give an insight which should be

undertaken first, also a time and cost indication is given.


10 Recommendations As can be imagined, no system is perfect. Of course there should be searched for the best

performance under the restricting budgets. After reviewing the system during the internship, ideas

to maintain and improve the system came into consideration. Some of these ideas are already

implemented, others take some more time to investigate or implement. Some will improve the air

quality in the buildings, some others will reduce the energy usage. An overview of the

recommendations for improving the system is generated. This overview contains a periodization and

an indication on the amount of time and/or cost it takes to implement the improvement. This

overview is generated in Dutch and can be found in Appendix 7. Because the amount of

recommendations, the ones with the highest priority will be discussed below.

High priority Time needed/ costs involved.

At the brewery, the ventilation units at BV1-BV3 have the most signs of wear. The reason for this is that these units have to process a lot of humid air. It is important for the working of the system that this corrosion should be removed. Small parts can be coated by an engineer. The condition of unit 1.7 and 1.1 is so bad that these should be revived. The ventilation units at the offices however are still looking good.

Much

The exhaust pipe of the pasteur, which has the goal to remove the moisture to prevent that this will go into the building, is just in front of the inlet of fresh air. In this way the moisture will still access the building. The more alarming is the effect of this moisture in the ventilation unit, these are subjected to lots of rust and corrosion. Find a way to move the outlet of the Pasteur of line 7.

Considerable

At the brewery all kinds of measurements are saved in order to analyze it. This is not the case of the ventilation system. Safe this information in order to be able to investigate if the system is working as it should be. The data that should be saved is for example the energy consumption of the heating, cooling and electricity. Thereby the setpoints of the different components are interesting.

Considerable

There are 3 outside temperature measurements on which the system is controlled. All these measuring instruments are weathered, causing unreliable measurements in the morning when the sun is shining. This leads to unnecessary consumption of energy during the summer days. The measuring instruments should be replaced

Little

At some locations at the brewery the air treatment units are permanently switched off. Being permanently switched off is bad for the state of the ventilation units and could give failures when suddenly turned on. Make sure each unit is switched on at least once a week.

Little

The HTHW network at packaging is broken at multiple points. The leakages already have already caused damage at the ceiling and dripped down beside the some control panels of the packaging lines. Make sure that these leakages will be repaired as soon as plausible.

Little

Heating is a considerable cost during the wintertime and consumes a lot of energy at packaging. Nevertheless the rook caps in BV1 and BV2 are standard opened for one third during the year. Also when the ventilation is switched off. Heating energy can be saved by closing these roof caps permanently when the ventilation is switched off. This will also prevent the entering of pollution in the building. By moving the air out of the building through the ventilation unit, more thermal energy out of the building can be reused.

Little


Some of the roof caps are located just in front of the suction grill for fresh outside air. This is the case for units 1, 2, 4, 5 and 7. Investigate the possibility to close these rook caps permanent. This will probably be a mechanical adjustment.

Little


11 References

[1] http://www.royalgrolsch.com/content/our-brewery

[2] http://www.royalgrolsch.com/content/our-beers-0

[3] http://www.royalgrolsch.com/content/history

[4] https://rijksoverheid.bouwbesluit.com/Inhoud/docs/wet/bb2012/hfd3/afd3-6

[5] https://puc.overheid.nl/doc/PUC_1174_14/1/#112487

[6] https://www.blygold.com/about-us/

[7] http://www.camfil.co.uk/About-Camfil-/

http://www.royalgrolsch.com/content/our-brewery

http://www.royalgrolsch.com/content/our-beers-0

http://www.royalgrolsch.com/content/history

https://rijksoverheid.bouwbesluit.com/Inhoud/docs/wet/bb2012/hfd3/afd3-6

https://puc.overheid.nl/doc/PUC_1174_14/1/#112487

https://www.blygold.com/about-us/


12 Appendix

12.1 Appendix 1: Milestone planning

Project milestones 'Project Ventilation System'Activity Resp. RAG 10 11 12 13 14 15 16 17 18 19 20 21 22

RL P 1 1 1

A

RL MB P 1 1 1

A

JK P 1 1 1

A

RL P 1 1 1

A

FG P 1 1 1

A

P 1 1 1 0

A

P 1

A

P 1 1

A

P

A

P

AIssue that w ill impact total project on time, cost or scope. Needs to be escalated by the project team

Issue that does not jeopardize total project on time, cost or scope. Can be resolved by project team

Performing to plan

Red

Amber

Green

1

2

3

4

6

7

8

5

Get an insight of the systems installed and provide an overviewJZ

Carry out a FMECA to discover the risks and criticalitiesJZ

Investigate if the maintenance performed is sufficient JZ

Analyze and optimize the controls of the ventilation system

JZ

JZ

Write report, make and present (end)presentation

Support

Present the intermediate results and conclusions at the monthly

meeting JZ

Finalize report based on feedback from end presentationJZ

Compare the system at Grolsch to those manufactured nowadaysJZ


12.2 Appendix 2: Overview of the components in the air treatment units Added file on server Grolsch: Samenvatting_inhoud_ventilatiekasten_en_luchtdrogers_Grolsch.xlsx

Naam Nummer op LBK Locatie Verdieping Aanvoercapaciteit (m^3/h) Aanvoercapaciteit (l/s) Afvoercapaciteit(m^3/h) Delta capaciteit (m^3/h) Aanvoer ventilator Afvoer ventilator Ventilator aansturing

Vernieuwde

controllers Locale afzuigventilator Dakkappen

Registers

buitenkanalen

Recirculatie

registers

Filter

Aanvoer

Filter

Afvoer

Bottelarij 1.1RK1 BV1 1 BV1 2 110.000 30.556 55.000 55.000 Ja Ja Meerdere setpoints Nee Nee Ja Ja Ja Ja Ja






Bottelarij 1.7RK1 BV3 7 BV3 2 110.000 30.556 55.000 55.000 Ja Ja 0 tot 100% Ja Nee Ja Ja Ja Ja Ja

Bottelarij 1.8RK1 BV3 8 BV3 2 110.000 30.556 55.000 55.000 Ja Ja 0 tot 100% Ja Nee Ja Ja Ja Ja Ja

30LBK30 HK6 2e verdieping 9 BV1 2 13.500 3.750 13.500 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Ja

31BK31 HK6 main lab 10 BV1 2 9.000 2.500 9.000 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Ja

Pasteur 5RK1 DT1 11 DT1 1 5.500 1.528 5.500 0 Ja Ja Laag en hoog toerental Nee Nee Nee Ja Nee Ja Nee

Kantoren / was -kleedruimten blok L DT1 12 DT1 1 7.600 2.111 6.775 825 Ja Ja Aan uit Nee Nee Nee Ja Nee Ja Ja

Kantoren / was -kleedruimten CM2 13 CM2 1 7.600 2.111 6.775 825 Ja Ja Aan uit Nee Nee Nee Ja Nee Ja Ja

Centrale magazijn 4RK1 CM2 14 CM2 1 20.000 5.556 0 20.000 Ja Nee Aan uit Nee Nee Nee Ja Ja Ja Nee

28LBK28 HK6 1e verdieping ( noord ) 15 HK6 1 10.000 2.778 10.000 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Ja

Kantoren/Kantine VG1 16 VG1 1 4.000 1.111 4.000 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Nee

Reclame 2RK1 RM1 17 RM1 1 1.200 333 0 1.200 Ja Nee Aan uit Nee Ja Nee Ja Nee Ja Nee

6LBK6 Repaking 6RK1 OP1 18 OP1 1 2.500 694 0 2.500 Ja Nee Aan uit Nee Ja Nee Ja Nee Ja Nee

7LB7 Rest.beer 6RK1 RB1 19 RB1 1 7.500 2.083 7.500 0 Ja Ja Laag en hoog toerental Nee Nee Nee Ja Ja Ja Nee

Control Room 20 BH2 2 7.000 1.944 7.000 0 Ja Ja 0 tot 100% Nee Nee Nee Ja Nee Ja Ja

Brouwhuis verdieping 21 BH2 2 86.500 24.028 86.500 0 Ja Ja 0 tot 100% Nee Nee Nee Ja Ja Ja Nee

Brouwhuis B.G. 22 BH2 3 63.500 17.639 63.500 0 Ja Ja 0 tot 100% Nee Nee Nee Ja Ja Ja Nee

26LBK26 HK2 23 BH2 3 18.750 5.208 18.750 0 Ja Ja 0 tot 100% Ja Nee Nee Ja Ja Ja Ja

33LBK33 HK4 1e verdieping 24 HK4 0 16.500 4.583 8.750 7.750 Ja Ja 0 tot 100% Nee Nee Nee Ja Ja Ja Ja

32LBK32 HK4 beganegrond 25 HK4 0 23.500 6.528 23.500 0 Ja Ja 0 tot 100% Nee Nee Nee Ja Nee Ja Ja

27LBK27 HK5 26 HK5 2 11.200 3.111 11.200 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Ja

34LBK34 HK4 2e verdieping 27 HK4 2 9.500 2.639 9.500 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Ja

25LBK25 HK1 28 HK1 2 11.200 3.111 11.200 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Ja

29LBK29 HK6 1e verdieping ( zuid ) 29 HK6 1 11.000 3.056 11.000 0 Ja Ja Aan uit Nee Nee Nee Ja Ja Ja Ja

Naam Verwarmingselement Koelelement Bevochtiger Ontvochtiger Druppelvanger Twin Coil Warmte Wiel Plaatwarmte-wisselaar WTW systeem Verlichting

Aantal

compontenten Locatie beschrijving Kolom1 Kolom2 Kolom3 Kolom4

Bottelarij 1.1RK1 BV1 Ja Nee Nee Nee Ja Ja Nee Nee Ja Ja 10 In de open ruimte boven BV1 aan de kant van het magazijn.








30LBK30 HK6 2e verdieping Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 In de open ruimte boven BV1 tegen de muur van HK6 aan de kant van het magazijn.

31BK31 HK6 main lab Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 In de open ruimte boven BV1 tegen de muur van HK6 aan de kant van BV1.

Pasteur 5RK1 DT1 Ja Nee Nee Nee Nee Nee Nee Nee Nee Ja 4 In technische ruimte die toegankelijk is vanaf BV2.

Kantoren / was -kleedruimten blok L DT1 Ja Ja Nee Nee Ja Nee Nee Ja Ja Ja 9 In technische ruimte die toegankelijk is vanaf BV2.

Kantoren / was -kleedruimten CM2 Ja Nee Nee Nee Ja Nee Nee Ja Ja Ja 8 In technische ruimte dat zich in de mannen kleedruimte bevind in CM2.

Centrale magazijn 4RK1 CM2 Ja Ja Ja Nee Ja Nee Nee Nee Nee Ja 7 Op hoogte in het magazijn, tegen de buitenmuur aan de kant van CM1. Bereikbaar via ladder.

28LBK28 HK6 1e verdieping ( noord ) Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 In ruimte naast de watertank van de sprinkler installatie, bereikbaar via wenteltrap naast de watertank.

Kantoren/Kantine VG1 Ja Nee Nee Nee Nee Nee Nee Nee Nee Ja 5 Op hoogte naast het kantoor aan de kant van VL2, bereikbaar via ladder.

Reclame 2RK1 RM1 Ja Nee Nee Nee Nee Nee Nee Nee Nee Ja 4 Op het dak van het kantoor, geheel in de hoek.

6LBK6 Repaking 6RK1 OP1 Ja Nee Nee Nee Nee Nee Nee Nee Nee Ja 4 Op hoogthe in de hoek met VG1 en RM1. Toegankelijk via trap ruimte zelf of via deur vanuit VG1.

7LB7 Rest.beer 6RK1 RB1 Ja Nee Nee Nee Nee Nee Nee Nee Nee Ja 5 Op hoogthe in de hoek met VG1 en OP1. Toegankelijk via ladder.

Control Room Ja 2 maal Nee Nee 2 keer Nee Nee Ja Ja Ja 9 In BH2 op de tweede verdieping tegen de buitenmuur en FK1 aan.

Brouwhuis verdieping Ja Nee Nee Nee Nee Nee Nee Nee Nee Ja 5 In BH2 op de tweede verdieping tegen de buitenmuur en BH3 aan.

Brouwhuis B.G. Ja Nee Nee Nee Nee Met LBK26 Nee Nee Ja Ja 7 In BH2 met trap naar de derde verdieping, in het midden van de ruimte tegen FK1.

26LBK26 HK2 Ja Ja Nee Nee Ja Met Brouwhuis Ja Nee Ja Ja 12 In BH2 met trap naar de derde verdieping, tegen uur van HK2.

33LBK33 HK4 1e verdieping Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 In de kelder van HK4, Met de lift naar de BG, links de trap naar beneden nemen. Achter kast 24, verdeeld over 2 kasten.

32LBK32 HK4 beganegrond Ja Ja Nee Nee Ja Ja Nee Nee Ja Ja 9 In de kelder van HK4, Met de lift naar de BG, links de trap naar beneden nemen.

27LBK27 HK5 Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 In technische ruimte bovenaan trap op tweede verdiepping.

34LBK34 HK4 2e verdieping Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 Op de tweede verdieping, midden op de verdieping in technische ruimte.

25LBK25 HK1 Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 In technische ruimte bovenaan trap op tweede verdiepping.

29LBK29 HK6 1e verdieping ( zuid ) Ja Ja Nee Nee Ja Nee Ja Nee Ja Ja 10 In technische ruimte in de gang van HK6 tegen BV1.

Betekenis kolommen schema

Nummer op LBK Elke kast heeft op de buitenkant in een groen blokje zijn eigen nummer staan.

Locatie Dit is de locatie waar de LBK staat. Dit hoeft niet hetzelfde gebouw te zijn als deze ventileert.

Verdieping Geeft aan op welke verdieping de LBK is gepositioneerd.

Aanvoercapaciteit (m^3/h) De hoeveelheid lucht die de aanvoerzijde van LBK per uur kan verwerken.

Aanvoercapaciteit (l/s) De hoeveelheid lucht die de aanvoerzijde van LBK per seconden kan verwerken.

Afvoercapaciteit(m^3/h) De hoeveelheid lucht die de afvoerzijde van LBK per uur kan verwerken.

Delta capaciteit (m^3/h) Het verschil tussen de luchtaanvoer en luchtafvoer.

Aanvoer ventilator Is er een ventilator in de LBK aanwezig om lucht aan te voeren

afvoer ventilator Is er een ventilator in de LBK aanwezig om de lucht af te voeren

Ventilator aansturing Op welke manier worden de ventilatoren aangestuurd? Vaste setpoint(s) of een 0-100% sturing.

Vernieuwde controllers Zijn er vernieuwde controllers geplaatst in de kast omdat de voorgaande verouderd en defect waren?

Afzuigventilator Sommige locaties hebben alleen inblaas via een LBK en een afvoer via

Dakkappen Op sommige locaties zijn er dakkappen aanwezig waardoor de lucht het gebouw kan verlaten.

Registers buitenkanalen Geeft aan of de aan- en afvoer kanalen van de LBK ge

Recirculatie registers Geeft aan of de LBK uitgevoerd is met een recirculatieklep om afgezogen lucht deels terug te het gebouw in te blazen.

Filter Aanvoer Word de buitenlucht gefilterd?

Filter Afvoer Word de afgezogen lucht gefilterd?

Verwarmingselement Is de LBK uitgevoerd met een verwarmingselement?

Koelelement Is de LBK uitgevoerd met een koelelement?

Bevochtiger Is de LBK uitgevoerd met een bevochtiger?

Ontvochtiger Is de LBK uitgevoerd met een ontvochtiger?

Druppelvanger Is de LBK uitgevoerd met een druppelvanger?

Twin Coil Is de LBK uitgevoerd met een twin coil?

Warmte Wiel Is de LBK uitgevoerd met een warmte wiel?

Platenwisselaar Is de LBK uitgevoerd met een platenwisselaar om energie terug te winnen?

WTW systeem Is de LBK uitgevoerd met een warmte terugwin systeem?

Verlichting Is de LBK uitgevoerd met een verlichting?

Aantal compontenten Is de LBK uitgevoerd met een aantal compontenten?

Locatie beschrijving Korte beschrijving waar de LBK gevonden kan worden.


12.3 Appendix 3: Inside of a ventilation unit

1 Registers

• Dicht

• Open

2 Filters

• Zakken

• Voorkant

• Binnenkant


3 Ventilator

• Aanzuigkant met elektromotor

• Uitblaaskant

4 Warmte terugwinningswiel

• Inblaas

• Afzuig

• Aansturing met riem

4b

Andere warmte terugwinning mogelijkheden

• Plaatwarmte-wisselaar

• Twin Coil

5 Verwarming

• Element

• Leidingwerk met regelklep


6 Koeling

• Element

• Leidingwerk met regelklep

7 Druppelvanger

8 Verlichting


12.4 Appendix 4: Overview of the components in the air dryers


12.5 Appendix 5: QFMECA (This file can be found on the server of Grolsch under the name: QFMECA_ventilation_system.xlsx)

0

Process Name: Luchtventilatiesysteem Brouwerij Prepared by: Jasper Zuurveld

Responsible: Jasper Zuurveld FMECA Date: 22-03-2018

Controls

Prevention

O

C

C

Controls

Detection

BrouwhuisLuchtverversing/temp

eratuurbeheersing

binnentemperatuur 29

gradenTe hoog

Mensen rondleiding

klagen, slechte

werkomgeving,

Instrumentatie

verslechterd

3 Geen 3

Geen automatische

melding, op eigen

inzicht of bij klachten.

3 27

Klep verwarming staat

handmatig open

Grote

toename

Geen

effect

Geen

effect

Verslechte

ring3 Geen 3

Geen automatische

melding, op eigen

inzicht of bij klachten.

3 27

Voorkomen dat kleppen

opengezet kunnen worden.

Met regelmaat controleren of

ze dicht staan

Packaging Luchtverversing1-4 keer per uur

tijdens productieTe weinig

Ophoping CO2 en

vocht zal niet worden

afgevoerd

4 2 4 32Batchgerichte

aansturing

Alle luchtregisters

naar buiten zitten

dicht

ToenameGeen

effect

Geen

effect

Verslechte

ring4

Softwarematig

ingesteld dat dit niet

zou moeten

voorkomen

2Geen terugkoppeling

binnen het systeem4 32

Met regelmaat visueel

inspecteren of alles nog naar

behoren werkt.

Luchtvochtigheid op

pijl houden40-60% Te hoog

Verhoogde kans op

bacteriegroei, vocht

kan neerslaan

5 3 3 45Dakkappen open bij te

hoge luchtvochtigheid

machines produceren

te veel vochtToename

Geen

effect

Verslechte

rd

Verslechte

ring3

Beter dichten en

isoleren wassers6

Het is visueel

zichtbaar dat er damp

opstijgt.

2 36

Vochtafgifte van machines

proberen in te perken, anders

lokaal actief afzuigen.

lucht wordt niet

genoeg ontvochtigd

Geen

effect

Geen

effect

Verslechte

rd

Verslechte

ring4 Meer lucht verversen 6

Ventilatiesysteem

pakt dit zelf aan. 2 48

Mogelijkheid onderzoeken of

ontvochtigen mogelijk is.

Aansturen op absolute i.p.v.

relatieve luchtvochtigheid

Meer lucht verversen,

betekend niet dat dit

drogere lucht is

Luchtvochtigheid op

pijl houden40-60% Te laag

Karton en papier

worden statisch4 2 5 40

Effect op karton, niet

op te merken op

product zoals bij te

vochtig

Te veel droge lucht

wordt er van buiten

naar binnen geblazen.

ToenameDaling van

kwaliteit

Verslechte

rd

Geen

effect 3

Minder

luchtverversing als

luchtvochtigheid laag

is.

3

Waardes aflezen op

computer, is geen

standaard handeling

5 45

Aansturen op absolute

luchtvochtigheid, momenteel

minder verversen.

Kantoren Luchtverversing

2-5 keer verversen

per uur tijdens

kantooruren

Te weinig

Ophoping van CO2,

productiviteit gaat

omlaag

5 2 4 40

Alle luchtregisters

staan dichtToename

Daling van

kwaliteit

Verslechte

rd

Grote

verslechter

ing

5

Softwarematig


zou moeten

voorkomen

2

Geen meldingen van

gebroken onderdelen,

klachten nemen toe

4 40



behoren werkt.

Luchtvochtigheid op

pijl houden40-60% Te laag

Meer ziekteverzuim,

lagere

gevoelstemperatuur

4 4 4 64

Droge lucht van buiten

word naar binnen

gezogen (koude

dagen)

Geen

effect

Daling van

kwaliteit

Verslechte

rd

Verslechte

ring4 Geen 3

In kantoren zijn geen

meters aanwezig. 4 48

Onderzoeken hoe groot dit

probleem is. Meters

ophangen. -> is al een

onderzoek naar gestart

Vooral met koud weer

Afzuigen vochtige

lucht

Geen

effect

Daling van

kwaliteit

Geen

effect

Verslechte

ring3

Geen, word zelfs niet

gemeten3

In bezoekersruimten

zijn geen RV meters

aanwezig.

4 36 Aansturen op luchtvochtigheidEffect versterkt door

centrale verwarming

Bezoekersruimte Luchtverversing

2-5 keer verversen

per uur tijdens

kantoor en

bezoekersuren

Te weinig Ophoping CO2 4 2 5 40

Alle luchtkleppen naar

buiten zitten dichtToename

Daling van

kwaliteit

Verslechte

rd

Verslechte

ring4

Softwarematig


zou moeten

voorkomen

2 Inspectie bij de kast 4 32

Software doorlichten om

erachter te komen

waarom/hoe dit zou kunnen

gebeuren

CO2 melder voor

aansturing geeft foute

waarde

AfnameGeen

effect

Geen

effect

Verslechte

ring3

Begrenzen welke

waardes aanvaardbaar

zijn

2 Metingen controleren 5 30

Er voor zorgen dat het

minimale afzuigniveau

voldoende is.

Luchtvochtigheid op

pijl houden

40-60%

Te laagNadelige gevolgen op

welzijn bezoekers3 3 4 36

Afzuigen vochtige

lucht

Geen

effect

Daling van

kwaliteit

Geen

effect

Verslechte

ring3


gemeten3

In bezoekersruimten

zijn geen RV meters

aanwezig.

4 36 Aansturen op luchtvochtigheidEffect versterkt door

centrale verwarming

Teveel droge lucht

naar binnen blazen

Geen

effect

Daling van

kwaliteit

Geen

effect

Verslechte

ring3


gemeten3

In bezoekersruimten

zijn geen RV meters

aanwezig.

4 36 Aansturen op luchtvochtigheid Vooral met koud weer

Koele opslagLuchtvochtigheid op

pijl houden

<40%

te hoogIjsvorming of condens

op tanks6 2 4 48

Droogfunctie van

luchtdroger is

uitgevallen

ToenameGeen

effect

Verslechte

rd

Geen

effect 6

onderhoud aan de

luchtdrogers 2

Melding op een

scherm3 36 Met regelmaat inspecteren

Main labVerwarmen van de

ruimte18-21˚C Te hoog

Nadelige gevolgen

voor micro5 3 3 45

Klep verwarming staat

handmatig open

Grote

toename

Daling van

kwaliteit

Verslechte

rd

Geen

effect 5 Geen 2 Geen 4 40

Regelmatig alle kleppen

langslopen en dichtdraaien.

Onderzoeken of dit

voorkomen kan worden.

Klep verwarming zit

vast

Grote

toename

Daling van

kwaliteit

Verslechte

rd

Geen

effect 5 Geen 2 Geen 3 30

Onlogische temperaturen

nalopen

Buitenlucht klep zit

vastAfname

Daling van

kwaliteit

Verslechte

rd

Verslechte

ring5

Uitlijnen en smeren

van de lagers 2

Melding op het

scherm3 30



behoren werkt.

Luchtverversing2-5 keer verversen

per uurTe weinig Ophoping CO2 5 2 4 40

Alle luchtregisters

naar buiten zitten

dicht

ToenameDaling van

kwaliteit

Verslechte

rd

Verslechte

ring5

Softwarematig


zou moeten

voorkomen

2

Komt er een melding

van, dat een actuator

niet werkt?

4 40



behoren werkt.

0

D

E

T

R

P

N

Actions Recommended RemarksEffect on

product

Effect on

process

Effect on

well-being

S

E

V

Current ProcessEffect on

energy

consumpti

on

Main potential causesBuilding section Function RequirementsPotential Failure

Mode

Potential Effects of

Failure


12.6 Appendix 6: Photo report (In Dutch) De foto’s zijn geordend in: Binnenkant LBK, luchtbuizen en rooster, leidingwerk HTHW en koeling, aansturing

en overig

Foto Locatie Wat te zien Probleem Oplossing

BV1, LBK1 Aanslag aan de binnenkant van de LBK

Roestvorming door versleten coating en vocht in de kast

Monteur: Nieuwe coating aanbrengen Engineering: Kast laten reviseren door externe partij





















BV3, LBK8 Luchtregisters staan maar deels open

De verse lucht moet door een veel kleinere opening. Dit geeft een groter verbruik.

Monteur: Registers afstellen en repareren.

BV1, LBK1 Schimmelvorming in de kast op de druppelvanger die na de twin coil geplaatst is aan de afzuigkant van de LBK

Door de vochtige en warme lucht uit de hal begint er schimmelvorming op te treden

Monteur: Reinigen van de druppelvanger



BV3, LBK7 Wegens lekkages aan het HTHW systeem is de condenswaterafvoer van de LBK losgekoppeld om het water van de lekkage af te voeren

Condenswater blijft in de LBK aanwezig. Ook wordt er nu valse lucht aangezogen via de losgehaalde afvoer.

Monteur: Lekkages HTHW systeem verhelpen waarna de afvoer weer in oude staat herstellen.

BV1, LBK1 Condenswater vormt zich in de LBK. In de winter stroomt de warme vochtige afgevoerde lucht langs een wand met registers waarachter de koude buitenlucht stroomt. Dit geeft condens op de wand en er is geen afvoer aanwezig.

Extreem veel vocht in de LBK. Dit bevordert de groei van schimmels.

Afvoer mogelijkheid toevoegen.

BV1, LBK1 Watervorming door condensvorming in de LBK

Vocht op plekken waar dit niet gewenst is. Corrosie vormt aan de onderkant van de LBK.

Engineering: Onderzoeken of er een afvoer geplaatst kan worden in samenwerking met een externe partij.

Bij meerdere kantoren

De afvoer van condenswater is afgesloten, omdat er rioollucht aangezogen werd. Dit gaf een rioolgeur in de kantoren.

Het condenswater dat zicht vormt in de LBK kan niet afgevoerd worden.

Monteur: Installeren van een nieuwe afvoer waar geen lucht door aangevoerd wordt.



BV1-BV3 Vuile inblaaspatronen van het ventilatiesysteem.

De vieze patronen boven het vullen ziet er niet hygiënisch uit. Zijn klachten van binnengekomen van de bezoekers van de brouwerij tour.

Technische dienst: Reinigen van de inblaaspatronen wanneer er te veel vervuiling op de patronen zit.

BH3 Stofophoping en vervuiling op het aanzuigrooster van de ventilatie van het brouwhuis begane grond en HK2.

Door de stofophoping kan de buitenlucht minder goed naar binnen komen. Vervuiling zal in filters komen.

Technische dienst: Reinigen van de roosters.

BH3 Inzuig van verse lucht brouwhuis en HK2 (rooster links onder) zit dicht bij uitblaas rooster van het brouwhuis (rooster op het dak)

Met een bepaalde wind wordt de lucht en geur van het brouwhuis bij HK2 weer naar binnen gezogen

-

BV3, dak boven afvullijn 7

De afvoer van het vocht van de pasteur voor het aanzuigrooster van de luchtbehandeling.

Er word veel vocht naar binnen gezogen, geeft roestvorming in de kast en hogere luchtvochtigheid in de hal.

Engineering: Zoeken naar een manier om de uitblaas van de pasteur te verplaatsen.



BV3, LBK8, afvullijn 7

Sporen van roest dat met condenswater uit de kast gelopen is.

Door het bovenstaande komt er overmatig veel vocht in de LBK. Hierdoor vorm er roest, wat vervolgens uit de LBK stroomt

Engineering: Zoeken naar een manier om de uitblaas van de pasteur te verplaatsen.

BV1, LBK1 Uitblaasroosters bij packaging zijn vies en zitten vol met schimmelgroei.

Schimmelgroei wil je niet hebben binnen de luchtbehandeling bij packaging.

Monteur: Reinigen van de uitblaasroosters bij packaging

BV2, LBK 5 afzuigkanaal

Vervuiling in de kanalen die de lucht afzuigen bij packaging.

Bij te veel vervuiling moeten de kanalen gereinigd worden. Momenteel is valt de vervuiling nog mee, dus is er nu nog geen probleem.

Monteur: Vervuiling in de buizen blijven controleren.

Aanzuig, alle LBK

Coating die uit de buizen komt aan de kant waar de buitenlucht wordt aangezogen.

De coating die bij het bouwen gebruikt is, was niet geschikt voor het materiaal waar de buizen van gemaakt zijn. Nu laat het los en kan er roestvorming ontstaan.

Engineering: Onderzoeken wat de gevolgen exact zijn en onderzoeken hoe dit probleem opgelost kan worden.

HK5, 1e verdieping

Schone aanvoerbuis van verse lucht. De filters doen hun werk goed.

- -



BV2, LBK5 Schone aanvoerbuis van verse lucht bij packaging. Ook hier doen de filters hun werk goed.

- -

BV2, LBK5 aanzuig buitenrooster

Vervuiling op de aanvoerroosters bij packaging.

De groei van vervuiling kan een kiem zijn voor bacteriën en bij loslaten zal het de filters vervuilen.

Monteur: Reinigen van vervuilde roosters bij packaging.

BV1, LBK1 Emmers zijn opgehangen aan het HTHW systeem om het water van de lekkages op te vangen.

Er zijn lekkages in het HTHW systeem.

Monteur: Het verhelpen van de lekkages.

BV1, LBK1 Er is een emmer geplaatst om het water van de lekkage van het HTHW systeem op te vangen.

Er zijn lekkages in het HTHW systeem.


BV1,LBK1 De bovengenoemde maatregelen werken niet voldoende, emmer zit vol en lekkages vinden plaats. Water stroomt over de vloer.

Er zijn lekkages in het HTHW systeem. De maatregelen getroffen zijn niet voldoende.




BV1, LBK1 Water stroomt vanaf de lekkages naar scheuren in de vloer waar het vocht in kan trekken. Het vocht trekt in het beton en lekt er door heen naar de verdieping eronder.

Er zijn lekkages in het HTHW systeem. Vocht trekt in de betonnen vloer en lekt er door heen.


Regelkasten kolonne 3

Het bovengenoemde water druppelt neer rondom de regelkasten van kolonne 3.

Water en regelkasten gaan niet goed samen. Groot risico tot kortsluiting resulteren in stilstand kolonne 3!

Monteur: Het verhelpen van de lekkages. Voorkomen dat water bij regelkasten kan komen.

Plafond BV1 Door de lekkages zijn de plafondplaten aangetast. Ziet er allemaal niet fris meer uit voor bezoekers brouwerij tour.

Plafondplaten zijn verkleurd door lekkages.

Monteur/installatie bedrijf: Vervangen platen met waterschade.

BV1-BV3 Lekkages bij een afsluiter van het HTHW systeem.

Kleppen worden jaarlijks een aantal keer geopend en gesloten. Door de hoge temperatuur van het water drogen deze kleppen uit en gaan lekken als er aan gedraaid wordt.

Engineering: Bepalen of deze lekkages er zijn. Indien dit het geval is de kleppen vervangen door kleppen die tegen de hoge temperatuur kunnen.

BV1-BV3 Nadat er aan de afsluitkleppen gedraaid is beginnen deze te lekken. Aan sporen op de grond te zien gebeurd dit al jaren.

De afsluitkleppen gaan lekker wanneer hieraan gedraaid wordt.

-



BV1-BV3 Wederom sporen van lekkages door sluiten kleppen. Ook een afgebroken handvat van een afsluitklep.

De afsluitkleppen gaan lekker wanneer hieraan gedraaid wordt. De handvatten breken af.

Engineering/ technische dienst: Nieuwe handvatten/ kleppen installeren.

Alle afsluiters HTHW netwerk

Handvat is afgebroken afsluiters HTHW systeem packaging

Na verloop van jaren op hoge temperatuur beginnen de handvatten af te breken.

Engineering/ technische dienst: Nieuwe handvatten of nieuwe kleppen plaatsen.

Verkleuring isolatie HTHW systeem

De isolatie is verkleurd door de hoge temperatuur van het HTHW systeem.

-

BV1, LBK Main Lab

Tape rondom een nieuw geplaatste pomp van het leidingwerk van de koeling. Bak om lekkages op te vangen.

En is geen nieuwe isolatie geplaatst/ beschikbaar. Lekkages zijn ontstaan door het plaatsen van de nieuwe pomp.

Monteur: Nieuwe isolatie plaatsen. Lekkage verhelpen.



BV1, LBK Main Lab

Isolatie van de leidingen van het koelnetwerk is extreem aangetast.

Isolatie van de leidingen van het koelnetwerk is extreem aangetast.

Monteur: Lekkages verhelpen en nieuwe isolatie plaatsen.

BV1, naast uitblaas LBK 1

Zwart verkleurde thermometer voor de buitenlucht en temperatuur.

Door de verkleuring wordt in de ochtend wanneer de zon erop staat, de temperatuur te hoog aangegeven. De meter geeft een buitentemperatuur aan, maar niet de temperatuur die aangezogen wordt.

Nieuw kapje plaatsen zodat de meting in de zon ook betrouwbaar is. De meter aan de aanzuigkant plaatsen zodat deze informatie geeft over de lucht die aangezogen word.

BV1, op de hoek van jet dak aan de aanzuigkant

Totaal vergaan weerstation. Temperatuurmeter hangt op de kop en de windrichting meter hangt scheef.

De metingen zijn niet meer betrouwbaar, maar de aansturing wordt hier wel op gedaan.

Monteur: Plaatsen van nieuwe meetapparatuur.

HK6.10.06 Thermometer in kantoor Suzan geeft 29.3 graden Celsius aan op een zonnige dag. De meter van het systeem eronder geeft aan dat het 35.6 graden is. Buiten was het rond de 25 graden.

De meter geeft een te hoge waarde aan. De temperatuur loopt binnen te veel op, blijkbaar heeft het kantoor niet voldoende koel capaciteit via de ventilatie.

Monteur: Meter vervangen/ kalibreren. Engineering: Een bedrijf inschakelen die de luchtstroom in HK6 zuid kan controleren en aanpassen.



Bedrijfsuren op computer scherm

De bedrijfsuren van verschillende onderdelen van de LBK bij packaging.

De meters kunnen niet verder dan 10.000 bedrijfsuren. Wanneer dit gehaald wordt, gaat de stand een beetje terug. Daarom is het aflezen van de bedrijfsuren onbetrouwbaar en kan er geen onderhoud op bedrijfsuren worden uitgevoerd.

Engineering: Ervoor zorgen dat de meters de daadwerkelijke bedrijfsuren aan geven. Dit geeft veel inzicht in het gebruik van de LBK.

LBK control room. Meter zit op alle kasten.

Een analoge meter die het drukverschil over de filtersectie meet.

Wanneer deze meters digitaal zouden zijn zouden de filters vervangen kunnen worden p[ het moment dat het drukverschil te groot zou worden. Nu worden de filters klakkeloos ieder jaar vervangen

Engineering: Plaatsen van digitale meters voor het drukverschil. Onderzoeken of aan de hand van het drukverschil de filters vervangen kunnen worden. Voor een test hiermee kan er eerst 1 LBK gedaan worden.

HK6, kantoortuin

Lichtbak voor natuurlijk licht in de kantoren.

De lichtbak is groot en laat daardoor veel warmte door. Hierdoor is het in de zomer niet koel te krijgen met de ventilatie.

Engineering: Onderzoeken of er een mogelijkheid is om het licht door te laten, maar de warmte buiten te laten.

HK6 noord, gang 2e verdieping

Lichtbak die is dichtgemaakt door plafondplaten

Mogelijke oplossing voor bovenstaande. Echter val het natuurlijke licht wel weg.

Engineering: Onderzoeken of dit een oplossing is tegen de warmte in de kantoortuin.


12.7 Appendix 7: Overview with recommendations (In Dutch) Geordend in prioriteit inclusief tijds- en/of kostenindicatie.

Hoge prioriteit Tijd/Kosten

De kasten in BV1-BV3 hebben de meeste vertoningen van slijtage. Dit komt door de grote hoeveelheid vochtige lucht die door de kasten gaan. Aanbevolen wordt om deze kasten als eerste een grote onderhoudsbeurt te geven, te beginnen bij kast 1.8 en 1.1. De luchtbehandelingskasten van de kantoren zien er allemaal nog goed uit.

Veel

De meters die de condities buiten meten, waarop het hele systeem geregeld wordt, zijn alle 3 verweerd. Het gaat hier 1 maal om een weerstation en 2 keer alleen een temperatuur en relatieve luchtvochtigheidsmeter. Deze geven daardoor gedurende zonnige morgens te hoge temperaturen aan. Deze meters dienen vervangen/opgeknapt te worden.

Redelijk

De uitlaat van de pasteur van lijn 7 zit recht voor in aanzuig van LBK1.8. Dit geeft extreem veel vocht en corrosie binnen de kast. Probeer de uitlaat te verplaatsen.

Redelijk

Start met het opslaan van de gegevens over het ventilatiesysteem. Momenteel kan er niet worden teruggekeken naar wat het systeem gedaan heeft, dit zou wel gewenst zijn om het gedrag te analyseren.

Redelijk

Zorg ervoor dat de alle luchtbehandelingskasten minimaal 1 uur in de week draaien. Momenteel staan er nog een aantal kasten in de brouwerij structureel uit, dit is uitermate slecht voor de kasten.

Weinig

Op meerdere locaties van het HTHW bij packaging systeem zijn lekkages gevonden. Deze lekkages hebben er tot 2 maal toe gezorgd dat er water rondom de regelkasten van de colonnes eronder stond. Zorg ervoor dat deze zo spoedig mogelijk gemaakt worden.

Weinig

In de winter kost het verwarmen bij packaging veel energie. Echter staan het hele jaar door de dakkappen voor 1/3 open, ook als de ventilatie uit staat. Hierdoor gaat er veel energie verloren door het dak. Een betere optie zou zijn om alle lucht door de LBK te laten gaan, zodat er meer energie teruggewonnen kan worden.

Weinig

Bij packaging zijn er een aantal dakkappen die de warme vochtige lucht afvoeren recht voor de aanzuig van verse buitenlucht. Het gaat hier om de kasten met nummer 1, 2, 4, 5 en 7. Onderzoek de mogelijkheid om die vijf dakkappen permanent te sluiten. Dit zal waarschijnlijk een mechanische aanpassing zijn.

Weinig

Matige prioriteit Tijd/Kosten

Vooral bij packaging komt het voor dat de kleppen, die de warmtetoevoer van het verwarmingselement regelen, warm water doorlaten. Dit zorgt voor extra warmtegebruik en te warme temperaturen in de hal. Het advies is om de HTHW leiding automatisch volledig te sluiten als de kasten geen warmte nodig hebben. Deze zullen ook automatisch openen wanneer er vraag is naar warmte.

Veel

Tijdens warm weer krijgt de ventilatie de temperatuur niet laag bij engineering, dit komt door de instraling van warmte van de lichtbak. Om het tijdens de warme dagen (25 graden of meer) relatief koel te krijgen zou er gekeken moeten worden om de instraling van warmte door de lichtbak te verminderen.

Veel

De relatieve luchtvochtigheid binnen de kantoren is structureel te laag. Dit heeft negatieve gevolgen op de gezondheid van de werknemers. Ook geeft dit een lagere gevoelstemperatuur gedurende de winter, waardoor er extra stookkosten zijn.

Veel


De luchtdrogers staan 24 uur per dag te draaien en gebruiken daarmee veel energie. Er bestaan mogelijkheden om de energie her te gebruiken binnen de luchtdroger. Op de website van Munters is daar meer informatie over te vinden.

Redelijk

De coating aan de binnenzijde van de luchttoevoer van alle luchtbehandeling laat los, dit zal in combinatie met de buitenlucht zorgen voor corrosievorming. Onderzoek de effecten hiervan en onderzoek hoe dit opgelost moet worden.

Redelijk

Een aantal van de dakkappen staat recht voor de aanzuig van verse lucht voor packaging. Onderzoek hoeveel effect dit heeft en of de mogelijkheid er is om deze dakkappen permanent te sluiten.

Weinig

De afvoer van het condenswater van de LBK van een aantal kantoren zijn doorgezaagd en afgesloten omdat er rioollucht aangezogen werd. Deze afvoer zit er echter niet voor niks, dus deze moeten wel weer gerepareerd worden.

Weinig

Lage prioriteit Tijd/Kosten

In LBK1.1 van packaging een keer een vacuüm ontstaan, waardoor de tussenwand met registerkleppen krom is getrokken. Deze wand is weer recht getrokken, maar sindsdien geven de registerkleppen regelmatig storing. Ze zijn al een keer gedemonteerd, zonder effect, dus onderzoek hoeveel het kost om een nieuwe registers te kopen.

Redelijk

Op de 2e verdieping van HK4 zit geen vast personeel. Af en toe worden er vergaderingen gehouden. Het ventilatiesysteem is daarom standaard uitgeschakeld en indien nodig handmatig ingeschakeld. Bij het plaatsten van een bewegingsmelder kan het systeem starten wanneer er langere tijd personen bevinden in HK4.

Redelijk

Met warme dagen is het in de ochtend vaak nog lekker koel buiten. Aangezien het systeem alleen op de buitentemperatuur regelt zal het warme kantoor in de morgen niet echt afgekoeld worden en in de middag juist meer moeten koelen. Onderzoek of de mogelijkheid er is om een temperatuur verwachting in het systeem te importeren en daarop het systeem te laten anticiperen.

Redelijk

De filters vervangen na het stuifmeelseizoen. Na dit seizoen zit er minder stuifmeel in de lucht, dus zullen de filters langer schoon blijven en dus minder energie opnemen.

Redelijk

Wanneer een pomp van het HTHW netwerk defect is komt dit vaak door de waaier die gebroken is. Momenteel word de pomp nu in zijn geheel vervangen, omdat de monteur niet in staat is om alleen een waaier te regelen. Naar verwachting zijn de waaiers wel los te verkrijgen, onderzoek of dit mogelijk is, kan ook hoop bestelkosten van nieuwe pompen schelen.

Weinig

De luchtbehandeling van het brouwhuis stond op maandagmorgen uit, juist wanneer de warmte uit het brouwhuis nuttig gebruikt kon worden voor het aanwarmen van HK2. Deze tijden zijn nu op elkaar afgestemd.

Geen


12.8 Appendix 8: Self-reflection on the internship at Grolsch Here I want to discuss my personal experience of the internship at Grolsch. While looking back on the

internship I can say that I have learned a lot during my time at Grolsch. It was a great experience,

working in a company with an actual production process. During the internship I was a member of the

engineering team, consisting of around 12 coworkers. Each of the coworkers has his own specific tasks,

making it clear who could give information over specific subjects. I had to consult with multiple people

of different departments and with different education levels. This made my internship very diverse,

being a connection between the mechanic and the engineers at the office.

After the first month of the internship I presented the intermediate results, in order to make sure that

the executed project would met the expectations of my supervisors. In addition to that I had on average

every week a meeting with Rob Leurink to discuss the progress. This was for me a convenient way to

hand over the information as soon as possible. I really appreciated the time Rob had for me. Small

question could be asked directly, cause Rob was located next to me in the so called “office garden”.

These gardens were a sign of the way of working at Grolsch, everyone was very open to each other.

The open garden was for me a good way of connecting to my colleagues. During the internship I started

to have discussions about what I have seen more openly with these colleagues. Also when it was not

about my assignment, but to help them with theirs.

Things I learned:

• Making contact with other companies, in name of Grolsch, and set up meetings with them. In

these meetings I had to be the chairman leading the conversation. This was something I never

experienced on the UT.

• The way of working in a company that is focused on producing and celling beverages. This

includes the focus on the main process and working with capex to improve and maintain the

process.

• Getting the reasonability for a subject and making sure that I deliver work on which Grolsch

could move on and make sure the ventilation will be properly working for the next years to

come.

Improvement points:

• I can be working on my own a lot, which is fine, but for the assignment it could be better to be

more open and discuss about the way I should deliver the work.

• I had a very broad assignment, on which I could spent a lot more time. The result of this is that I

sometimes spend time on things that at the end never will be used. Therefor keeping more

focus on the assignment during the internship will be a learning goal the next time.

• During the internship I was a bit reservedly in discussions with others, this holds also during

presentations. Therefor I should “man up” and get some more personality to improve the way I

made my points.

The next time I have to do an assignment at a company I would like to have an assignment that consist

of optimizing a process. During the time at Grolsch I liked the jobs of Rob and Martin a lot, they were

both optimizing the processes. One the processes at packaging, the other the processes at the utility

building. For future careers I would like to gain an opportunity in this kind of work area.

At the end, it was a great opportunity for me to learn and grow in my experience of working in an

engineering environment. It gave me insight in the way of working I could experience after graduating

for my master mechanical engineering at the University of Twente.

analysis of the ventilation system - universiteit...

Documents