Energy Sytems and their maintenance slides

1. Energy
Shams Mawji
Taha Uzair
Systems
Maintenance

2. Introduction
• Maintenance is a critical part of a
facility’s operation
• For optimum functionality, maintaining
equipments and processes are
necessary
• Usually efforts towards repair and
replacement rather than keeping the
equipment running most efficiently

3. Objectives
• Highlight role of
maintenance as it relates to
energy costs
• Discuss maintenance aspects
of each major energy-
consuming sector of a facility
• Importance of a continuous improvement approach

4. Benefits of Maintenance
• Keeps equipment from failing
• Necessary for safety
• Helps maintain energy costs
within reason
• Helps prevent excess capital expenditures
• Contributes to the quality of a product

5. Energy Management Maintenance
Program
Planning/
Analysis
Action
Monitoring
Analysis

6. Continuous Improvement
Maintenance Program
• Planning
• Forming a maintenance team
• Establishing goals
• Estimating present maintenance costs
• Identifying maintenance tasks that
need to be carried out
• Setting priority
• Monitoring, analysing and taking new actions

7. Identifying Energy Related Maintenance Functions
• Identifying maintenance activities that contribute
most to energy efficiency improvement or which
result in significant energy use
• Most process maintenance functions and many
building maintenance functions are energy related.
Some maintenance operations are also energy
related e.g. night time cleaning
Planning

8. Estimating Present Energy-related Maintenance Costs
• Important to judge end-of-year accomplishments of
the energy maintenance effort
• Cost of labor – wages/salaries of maintenance staff
(personnel or contractors) – estimate percentage of
time spent by each maintenance personnel on
energy-related maintenance
• Costs to keep the energy systems functioning
Planning

9. Energy systems include:
• Boilers
• Steam distribution system
• Lighting
• HVAC and Industrial Refrigeration
• Building envelope
• Hot water distribution
• Air compressors and the compressed air distribution
system
• Electrical distribution
• Manufacturing processes
Planning

10. • Cost of material – costs of the
systems themselves and the
costs of any replacement parts
– manufacturing process
equipments are not included
• Indirect costs – costs that arise
due to maintenance actions
e.g. a piece of production
equipment breaks down
because of poor maintenance
practices
Continued

11. Determining the Present Condition of the Major Systems
How to go about?
• Inspection of the major systems
• Include operators of equipment in the inspection
process – since they are more familiar with the
problems of operating the equipment
• Maintain a log of maintenance problems together
with the date of inspection
Planning

12. Every year a boiler goes without attention, it costs an
additional 10% in boiler energy costs
Boiler Gauges
•Operating & readable
•If any gauge is not
working, control system
should have immediate
attention
•Rust in gauges, tubes
and water piping need
to be cleaned to restore
acceptable heat transfer
rates
Boiler Controls
•Regulate amount of combustion air – if too much
air, much energy goes up the stack & heats the
outside air – if too little air, boiler smokes, explosion
hazard
•Flue gas analysis to see whether boiler operating
with right amount of air
•Regulate level of water to prevent overheating & to
provide room for steam
•Control amount of fuel entering boiler
•Monitor flue gas temperature
•Control system is the major defense against boiler
explosion
•Monthly tune-ups or at least twice a year
Boilers and the Steam Distribution System

13. Steam Traps
• Steam traps separate steam from
condensate
• Condensate absorbs heat from
steam, thus reducing heat transfer &
because returning hot condensate
to boiler reduces the amount of fuel
required by the boiler
• If trap fails open, steam passes into
condensate & its heat is wasted
• If it fails shut, then the steam
distribution system has an excess
burden of condensate, thus slowing
heat transfer & increasing the
weight the distribution system has
to carry
• Traps can be checked visually by
stethoscope or by the use of
infrared and ultrasound equipment
Water treatment
• Correct treatment of water entering
boiler is necessary to prevent build up
of scale, reduced heat transfer and
failure of tubes
Steam Lines & Condensate Lines
• Leaks in steam lines can reduce both
pressure and amount of steam
delivered
• A ½” hole on 600psig line can cost
as much as $25,000 per month
• IR scanning devices are useful for
detecting steam leaks
• Hot condensate is reused, thus saves
some fuel, saves cost of purchasing
or producing replacement water &
as it has been treated, saves cost of
treatment against impurities to
prevent scaling
• Cost of draining condensate into
facility’s waste water system is saved
to some extent

14. Motors
- Motors account for at least 50-70% of
electricity consumption at any facility.
- Problems faced by Motors:
* Worn bearings
- flat spots
- dirt particles
* Voltage imbalance
- heat build up
* Inadequate lubrication

15. Lighting
• Importance of Lightning:
* It uses electricity
- extra amount is always required to prevent
levels falling below required levels.
* It produces heat
- HVAC plant needs to remove any excess heat.
* Lighting and productivity are linked
- 6% increase in output + significant reduction
in errors at a postal service
* Maintenance issues
- whether continuous or periodic replacement
should be chosen

16. HVAC and Industrial Refrigeration
• Operating times and temp. of
HVAC plant can help in cost
reduction.
• Maintenance improvements:
* Ductwork – damages/
leakages can lead to loss of
conditioned air.
* Heat transfer surfaces –
heating/cooling coils, fins can get covered by dirt.
* Cooling towers – scaling/debris build up can
significantly increase energy consumption.
* Filters – air filters require regular checks for clogging

17. The Building Envelope
• Any maintenance program should contain inspection
of the building envelope.
• Even small leakages can end up costing a lot of
money.
* Doors & windows – cracks and gaps around
them should be properly sealed.
* Roof insulation – very important, specially in
extreme climates where heat transfer can cost a lot.

18. Hot Water Distribution
• Temperature controls:
* gauges become inoperable
from fouling and bumping.
* Displays need to be checked
• Leaks in electrical systems can be
hazardous.
• Valves – distribution flow rates
need to be kept under control
• Insulation – if exposed, it is susceptible to truck lift
damage. After identification, faulty components
should be removed ASAP.

19. Air Compressors and Distribution
• Compressed air is a source of power or used as a
medium of controls.
• Air compressor – these parts need to be checked:
* heat transfer fins – dirt, debris build up
* compressor gaskets – noise and leak free
* connections shouldn’t leak
*Dryer needs to be functioning. Moisture can
cause controls and piping deterioration
• Leaks in compressed air are expensive and can cause
controls malfunction.

20. Prioritizing Maintenance Tasks
• Safety related problems should be addressed
immediately
• Prioritize other tasks with respect to their
contribution to saving energy
• Pareto Analysis is a helpful tool
• Impact on the overall productivity also considered

21. Pareto Analysis
Part Hours to Repair Hours Down
Heating Element 537 1497
Vacuum 218 407
Rebricking 184 552
Roughing Pump 95.5 95
Oil Seal 65 145
Thermocouple 64 96
Chain 48 144
Shear Pin 41 89
Latch 40 104
Insulation 36 84
Panel 35 35
Chart Recorder 32 96
Transformer 24 24
Holding Pump 19.5 19.5
Defusion Pump 16 0
Door 15 15
Fuse 12 26
Blower 11 11
Backfill 9 9
Booster 8 8
Hearth Support 8 8
Load Rail 8 0
Cabinet Fan 4 4
Filter Pump 3 1
Circulation Fan 3 0
Temperature Control 2 2
Oil Pump 1 1
0
100
200
300
400
500
600
Hours to Repair
Hours to Repair
0
200
400
600
800
1000
1200
1400
1600
Hours Down
Hours Down

22. Ongoing Preventive Maintenance
Tasks
Equipment
description
Maintenance and
equipment needed
Frequency Skills Maintenance time Spare parts
needed
Priority
100 hp motor in
corner of weave
room
Check front and
rear bearings on
motor for hot spots
using IR gun
6 months Trained in IR Depends on facility Replacement
bearings
Every facility has
its own priorities
Maintenance Data Table

23. Electrical Distribution
• Transformers contain dielectric fluid,
heat sinks, and isolation guards, and
they must be inspected and repaired
regularly.
• Junction boxes need to be checked
for shorts, frayed wires, arcing and
burned insulations.
• Grounding inadequate grounding can damage the equipment.
Manufacturing Process Equipment requires regular maintenance,
repairs, and replacements.
Waste Reduction:
• Increase efficiency – reduce energy consumption

24. Develop Initial Monitoring
Procedures
• Maintenance logs - to put all the
maintenance information onto an easily
accessible spreadsheet.
• Portable devices
- small battery powered devices that log raw data such
as temperature, voltage, light intensity, etc.
- led to a great increase in the efficiency of
maintenance.
• Semi-permanent monitoring
Equipment