green buildings : challange in operation and maintenance

Living in harmony with Nature

Challenges in Operation & Maintenance of Green Buildings

Dec 2012

ISHRAE : Acre Serve

Tejwant NavalkarExecutive Director – DFX Systems Pvt Ltd

Living in harmony with Nature AGENDA

Green Buildings – Concepts Review of Current Maintenance

Practices Need for “Green Maintenance” Monitoring for effective Control Shift from Reactive to Predictive

Maintenance Conclusion


Green Buildings are :• Resource efficient buildings • Very energy efficient, • Utilize construction materials wisely; including

recycled, renewable, and reused resources to the maximum extent practical

• Are Designed, constructed and commissioned to ensure they are healthy for their occupants,

• Have lower operating and owning costs, • Respect and maintain ecological balance• Are good for the earth planet

What are Green Buildings


• SustainabilityMeeting the needs of people today without destroying

the resources that will be needed by future generation• Energy Efficiency

Using Equipment which require lowest input energy to deliver their outputs

• Efficient Water ManagementImplementing effective control on water usage, minimising

wastage of water, recycling waste water and judicious selection of landscape plants

• Recycling and reuse of Materials• Indoor Environmental Quality

Monitoring and controlling the quality of air circulated through air- conditioned spaces, providing lighting levels for minimal eye strain and ensuring noise levels are within comfort zone

Factors contributing to Green Buildings (1/2)


• Environmental ConcernResponsible disposal of waste, recycling of waste and use of non-ozone depleting materials

• Infrastrucutre Planning Providing good Infrastructure in terms of clean, stable

power, good regular supply of potable water and efficient waste disposal, combined with easy access to public transportation.

• Use of Renewable EnergyEnsures virtually Zero Global Warming and provides self

reliance from external agencies in meeting its energy needs

• Staff and User TrainingTraining individual users, owners, staff and inhabitants

of buildings in avoidance of wastage, recycling, correct use of equipment and the importance of effective maintenance in ensuring optimum efficiencies at all times

Factors contributing to Green Buildings (2/2)

Living in harmony with Nature Some Interesting Photos (1/3)

Rusted chilled water pipe Broken Insulation chilled water pipeRusted chilled water pipe

Broken Insulation on Valves

Badly dressed cablesCables connected without lugs Badly laid cables


Badly maintained condenser piping

Badly maintained Cooling Tower

Rusted Chilled water piping

Badly dressed cables Cables dangling in the open

Unarmoured cable laid in water


Badly maintained plumbing pipes Badly maintained AC

outdoor units on terraceOpen Manhole covers

Badly maintained Pumping station

Terrace – Dumping PlaceWater logged terrace


• Today a majority of the maintenance is re-active in nature

• Scheduled Maintenance Programs are done on a few equipment based on :

the manufacturers recommendations judgement of the chief or past tradition

• Log books are maintained for a few equipment

where hourly readings of certain parameters are recorded

• Very rarely are these readings analyzed or collated to generate a trend analysis

• No on line measurement of energy or water consumption by energy centres

• No effective equipment replacement plan

Current Maintenance Practices (1/3)


• There is no organized Complaint Management System

• Complaints are noted in a register and attended on a best effort basis

• There are no standard time to repair, no history of complaints and no mean time between failure (MTBF) records being generated from the complaints completed

• Due to lack of complaint history, the present stocking of spares is almost entirely based on serendipity; either it is never stocked or it remains a non-moving item for years

• Air-balancing, room temperatures, diffuser/ grille temperatures are very rarely measured

• Water Analysis of the cooling tower make-up water or boiler feed water is rarely done on a planned basis

• Insulation of pipes, ducts is rarely checked and repaired



• No thermography is done on electrical panels to detect any corrosion in joints or any loose connections

• Cables after repairs are not properly dressed• Light fittings are not cleaned as a part of

routine maintenance• Lux levels in work areas and cabins are never

measured • No effort is taken to identify over designed or

under designed equipment • AHU rooms, Electric meter rooms become

dumping yards for all sort of boxes, unwanted material, chairs etc.


Living in harmony with Nature GREEN Maintenance Practices

• Effort should be taken to shift from Re-active Maintenance to Pro-Active Maintenance and eventually to Predictive Maintenance

• Electric sub-meters, connected to a central energy monitoring system, should be installed at each energy consumption centre

• Daily, Monthly and Annual reports should be generated from these energy consumption readings for analysis

• After analysis, efforts should be taken to identify the ways and means of :

Reducing Maximum demand Utilising lower night time tariffs and

avoiding peak time consumption• Similarly water sub-meters should be installed at

major consumption centres


0

1000

2000

3000

4000

5000

TIME OF DAY

EN

ER

GY

kW

TOTAL

Base Load

Peak Load

Daily Energy Consumption in a Typical Industry

• Energy Consumption Pattern above depicts the following characteristics during its 24 hour cycle :

A base load of about 40-50% of the peak load About 3 - 4 peaks during the day

• Peak Loads decides the Maximum Demand and consequently the Power Tariff


• Introducing Controls in a running building may be difficult

• However it is possible to introduce instruments to : Analyze critical Operating System Parameters Measure Energy Consumption at distributed

stages in the process Automate Start-up/ Shutdown of processes Generate Alarms/ Reports during exception

conditions

Analysing Daily Energy through instruments


0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5Time of Day

Ene

rgy

kW P-4 P-3 P-2 P-1

Peak Load

Break-up of Daily Energy Consumption

• Based on break-up of daily energy consumption at distributed consumption centres, it is possible to :

Impose Energy Demand Load Limits Impose Constraints of usage Requirements Optimize the overall operation Evenly distribute energy loads to reduce

peaks Take advantage of Time of Day Tariff

Living in harmony with Nature Effect of Re-Engineering

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5Time of Day

Ene

rgy

kW

P-4 P-3 P-2 P-1

Modified Peak Load

Old Peak Load


Average Power Consumed for a day : Pharmaceutical Company

Energy Measurements – Case Study

Living in harmony with Nature Energy Measurements – Case Study

Power Consumed by a Compressor for a day : Pharmaceutical Co

Living in harmony with Nature Energy Measurements – Case Study

Thermography of Electric Panel : Processing Lab

Living in harmony with Nature Identification of Over/ Under designed Motors

Sr No

Description Rated KW

Max KW Consumed

Avg. KW Consumed

Diff of Rated KW over Max

KW

Diff of Rated KW over Avg

KW 1 ETP Compressor 7.5 HP 5.60 0.38 0.31 14.74 18.06 2 Air Washer No. 2 7.50 1.30 1.24 5.77 6.05 3 AHU-5 Fan 11.00 2.75 2.64 4.00 4.17 4 Extruder Motor Repocessing Plant 30.00 9.85 8.64 3.05 3.47 5 Distillation C. T. Pump 7.50 2.90 2.80 2.59 2.68 6 Air Washer No. 1 15.00 5.91 5.72 2.54 2.62 7 AHU-1, 2, 3 & 4 Fans 18.50 10.10 9.59 1.83 1.93 8 ETP Pump 5 HP 3.70 2.03 1.98 1.82 1.87 9 Solution Cooling Tower Pump 7.50 4.64 4.20 1.62 1.79

10 Autoclave Exhaust Fan 5.50 3.43 3.32 1.60 1.66 11 Grinder Motor Repocessing Plant 11.00 7.25 6.34 1.52 1.74 12 Boiler Blower Fan 22.50 15.26 11.62 1.47 1.94 13 Booster Pump 3.70 2.55 1.54 1.45 2.40 14 Autoclave-1 22.00 16.07 10.59 1.37 2.08 15 Hot Cold Circ. Pumps 3 & 4 7.50 5.48 4.81 1.37 1.56 16 Autoclave-3 9.30 7.01 3.24 1.33 2.87 17 Cooling Tower Pump (25 HP) 15.50 13.15 12.41 1.18 1.25 18 Compressor – No. 1 45.00 38.19 18.70 1.18 2.41 19 Compressor – No. 2 45.00 39.42 38.40 1.14 1.17 20 Boiler Feed Water Pump 15.00 14.32 2.99 1.05 5.02 21 Hot Cold Circ. Pumps 1 & 2 5.50 5.46 5.19 1.01 1.06 22 Chilled Water Pump 9.30 9.28 9.05 1.00 1.03 23 Reverse Osmosis Multistage Pump 11.00 11.00 5.39 1.00 2.04 24 Autoclave-2 9.30 9.61 7.95 0.97 1.17 25 WFI Pump 7.50 10.60 6.65 0.71 1.13 26 Ultra Filtration Pump 3.73 6.41 3.64 0.58 1.02

Living in harmony with Nature Health Monitoring of Equipment

• Critical health parameters of equipment must be identified and on-line measurements of these parameters provided to give and insight into the health of the equipment

• In some cases, like dirty filter or water flow switches, alarms may be generated if the threshold conditions are crossed

• Threshold conditions can be established for each of the health parameter for an equipment, much like that of a human being

• By continuous measurement of the health parameters, we can move towards predictive maintenance, ensuring against expensive, unplanned and forced shutdowns

• By giving each machine its own customized treatment the life of the equipment is increased and its initial efficiency retained for longer period


Winding Temperature Sensors

Vibration Sensors Current Consumption

Rotation Speed

Data Acquisition & Control System

Equipment Monitored

Computer Workstation

EQUIPMENT HEALTH MONITORING SCHEMATIC

Equipment Health Monitoring

http://www.homeshop18.com/shop/u/y/p-Computers-Q-and-Q-Peripherals-S-Desktops-S-Zenith-Q-Desktop-Q-Model-Q-No:-Q-G31643/Home_Online-pI_27771-clI_2-cI_919-pCI_909-











Living in harmony with Nature On-line Complaint / Breakdown Manangement System

• On-line Complaint/ Break-down Management system should be introduced

• This would help in building complaint history for each equipment and provide valuable information regarding mean time between failures, replacement indication and build complaint history

• Complaint History would provide effective means for deciding on spares stocking

• Complaint Management coupled with the Equipment Health Monitoring, provides the right tools for predictive maintenance

• Efficiencies of each equipment can be effectively monitored

Living in harmony with Nature Other GREEN Maintenance Practices

• Ensure that the Fresh Air Dampers and other Volume control dampers are in working condition

• Ensure that all insulated piping and ducting is proper and no air leakages occur in ducting above the false ceiling

• Use of bio-degradable organic chemicals for anti-scaling and anti-algae formation in cooling tower basins

• Explore avenues for introducing energy efficient light fittings and other equipment

• Introduce Renewable Energy resources wherever feasible especially for 24-hour operating lights

• Educate and train all staff in the importance of avoiding wastage of resources and recycling of material


Tejwant Navalkar : +91-9821411436 [email protected]

Contact Details

DFX Systems Pvt LtdEngineering & Renewable Energy Solutions

Your Partner

in

Designing For eXcellence www.dfxsystems.org

Tel: 91-22-2432 4083Fax: 91-22-2432 5644