Case Studies on Energy Cost

Saving
( Energy Systems Maintenance )
Presented by: Cezar and Umbao
 Energy Systems Maintenance is the
maintenance of all systems that use or
affect the use of energy.

INTRODUC Found in every kind of organization

that uses energy, whether a hospital, a
TION church, a store, a university, a
warehouse,
Energy or Maintenance
Systems a factory. includes
routine maintenance tasks as lubrication,
examination, and cleaning of electrical
contacts and calibrating thermostats, and
non- routine tasks as repainting walls to
increase the effective lightning, cleaning fins
on compressors, and cleaning damper blades
and linkages.
 A good energy systems
maintenance program can
save a company substantial
amounts of money in wasted
steam and wasted electricity
and in the lost production
and additional expense
caused by preventable
Other benefits
equipments include
breakdowns.
INTRODUC general cleanliness,
improved employee
TION morale, and increased
safety.
In a good maintenance
program, planning,
scheduling, and
monitoring are all
carried out in a
predictable and well-
organized manner.
 Developing The
Maintenance Program
Four Steps:

Step 1, is to determine the present condition of

the existing facility.
This step includes a detailed examination of
each of the major energy-consuming systems.
Step 2, is the preparation of a list of routine
maintenance tasks with an estimate of the
number of times that each task must be
performed.
This list includes for each task, the craft, the
needed material, and appropriate equipment.
Step 3, is a regular schedule for the
accomplishment of the desired maintenance.
Step 4, is the monitoring necessary to keep the
program in force once it has been initiated.
 The purpose of this step is to
create a starting point. The
questions to be answered are:
Step 1,
1. What equipment and systems
Determine are in the building?
the Present 2. What material is available to
describe each system and/ or its
Condition of components?
3. What needs to be done to get
the Facility the energy related systems into
working condition and to keep
them that way?
Step 1 This step should incorporate:
1. Vendor data and operating
specifications for as much of the
installed equipment as possible,
kept in a notebook, a file cabinet,
or a computer database.
2. A diagram of each major system,
showing the location of all
important equipment and the
direction of all fluid flows.
3. A complete list of all the
equipment in the building, showing
the name, location, and condition
of each item
4.A comprehensive list of
maintenance tasks required for
each piece of equipment.
Classification Building Envelope
Boilers and Steam Distribution
of Energy Systems
Heating, Ventilating, And Air
Systems – Conditioning
Energy Electrical System
Lights, Windows and Reflective
Consumption Surfaces
Analysis of Hot Water Distribution System
Each Air Compressors and Air
Distribution System
The Manufacturing Equipment
Equipment
System
 THIS THE THE
CONSISTS PRIMARY
OF ALL MALFUNCTIO BENEFITS
PARTS OF N OF THIS FROM
Building THE
FACILITY
SYSTEM IS
LEAKAGE OF
AIR, AND
MAINTAIN
ING THIS
Envelope THAT CAN
LEAK AIR
INTO OR
THIS
LEAKAGE
CAN OFTEN
SYSTEM
ARE:
OUT OF ANY BE
BUILDING. DETECTED
1. BY SIGHT- 2.
LOOKING
REDUCTI INCREASE
FOR CRACKS-
ON IN THE OR BY D
AMOUNTNOTINGCOMFORT
THE
PRESENCE OF
OF AIRA DRAFT.DUE TO
THAT DECREAS
Table 14.1 Problems and
solutions: the building
envelope
 A boiler is often the largest
consumer of fuel in a
Any improvements
factory or building. that
maintenance can make in
Boilers and its operation are therefore
immediately reflected in
Steam decreased
If the Steam
consumption
energy
distribution
andordecreased
system has leaks is not
Distribution energy
properlycost
insulated, these
faults cause the boiler to
Systems generate more
Boilers can steam than is
malfunction,
needed.
and steam leaks can cause
severe burns if maintenance
is performed by untrained
personnel.
 Table 14.2 Problems and
Solutions: Boiler and Steam
Distribution System
 Purposes of these systems are to supply
enough air of the right temperature to
keep people comfortable and to exhaust
harmful or unpleasant air contaminants
Significant amounts of money may be
saved by proper maintenance of this
Heating, system.
These saving come from three
Ventilating, sources:
and Air- 1. Reducing the energy used by the
system and its associated cost.
Conditioning 2. Decreasing the amount of
unanticipated repair that is
necessary in the absence of good
3maintenance
. Reducing downtime
. caused when
the system does not work and
conditions become either
Table 14.3 Problems and solution: Heating,
Ventilating and Air-Conditioning System
 If a motor is operating at a lower voltage than it
was designed for, it is probably using more
amperage than was intended and is causing
unnecessary losses in transmission lines.
If the wires are too small for the load, line
losses can be large, and fire hazards
increase significantly.
Other problems that can create
Electrical unnecessary energy loss are voltage
imbalance in three phase motors and leaks
System from voltage sources
It is desirable to haveto ground.
a qualified
electrician or electrical contractor
examineyour facility to find safety
problems.
Another problem that may cost money is a
lower power factor. The power factor is the
ratio between a resistive component of AC
power and the total supplied.
Table 14.4 Problems And
Solutions: Electrical
System
 The energy consumed by
lights is significant, as is
the energy used by heating,
ventilating and air
Lights, conditioning
Many factorssystem
modifytothe
remove the heat putlighting
into a
Windows effectiveness
building
system ofby
of the
the lights.
a particular
and importance are the
condition of the lights, the
Reflective cleanliness of the
luminaries, and the
Surfaces cleanliness of the walls,
ceiling, and floors.
Windows can also be a
source of light, so it should
be cleaned.
 Table 14.5 Problems and
solutions: Lights, Windows
and Reflective Surfaces
 It can be used for sterilization, for
industrial cleaning, as a source of process
heat or for washing hands.
The maintenance principles for all of these uses
are the same, but the temperatures that must be
Hot- Water maintained in this area is to keep temperatures as
low as possible, to prevent leaks, to keep insulation
Distribution in repair and to keep heat transfer surfaces clean.
A further area for improved maintenance
System is the insulation of hot water tanks and
lines.
Heat transfer should examined and fins
or radiators that are plugged up with
debris or dirt are causing the hotwater
heater or consume more energy.
Table 14.6 Problems and
Solutions: Hot- Water
Distribution System
 Compressed air serves one of the three
functions:

Air As a control medium, it serves to regulate various parts

of heating, ventilating and air conditioning systems

Compressors As for cleaning, can be used to dry materials or blow

away various kind of dirt.
and the Air As a source of energy tools or machines, can be a

Distribution convenient source of energy tools or for various kinds of

hydraulic equipment.

System All three uses are affected badly by line leaks and by
poor compressor performance.
Another thing controls are particularly affected by oil,
water and dust particles in air, so it is utmost importance
that the compressor be checked regularly to see that the
air cleaner is working as intended.
 Table 14.7 Problems and
Solutions: Air Compressors and
the Air Distribution System
 in manufacturing,
common to many
companies or facilities
and has unique
maintenance
Motors – can consume excess
The amounts of energy if they are
requirements
improperly mounted, this
if they are not
includes
hooked up toMotors, Ovens
their load or in the
Manufacturi case
and ofTime
three phase motors, if the
Clocks.
voltages in the opposing legs are

ng
different.
Ovens – use much energy and many
standard operating practices are
Equipment available to help decrease
associated waste. Actions that must
Time Clocks – the
canseals,
be used to
System
performed, check
significant advantage
controls, refractory in the
and insulation.
control of equipment that
can ge turned off at regular
intervals.
 Table 14.8 Problems and
solutions: The Manufacturing
Equipment System
Step 2, Prepare a List of Routine
Maintenance Actions with Time
Estimates, Materials, and
Frequency for Each
The products of this step are:
1. a list of all the equipment in the facilty by
system.
2. a list of major one time maintenace
problems associated with this equipment.
3. a notebook with these lists and with the
diagrams for each of the major systems.
The list should be maintained in a form that
maintenance personnel can use them.
Time Standards – accurate time standards
for maintenance are difficult to obtain
except where the maintenance actions are
the same whenever they are repeated.
Table 14.9 Table of Preventive Maintenance
Actions
 Step 3, Prepare a
Maintenance Schedule
To develop your own
maintenance schedule, first list
the equipment you have in your
facilty, then using the table,
estimate the maintenamce or
inspection frequencies for each
unit.
The master table and the
workbook are used to develop
two files: Equipment file and
Tickler file.
Table 14.10 Example of
Equipment Maintenance
and Frequencies
 Figure 14.1
Equipment Record
Step 4, Follow-up Has three objectives:
and Monitoring
1. to ensure that the maintenance is being
performed as scheduled.
2. is for the manangement to get an update
on the condition of the facility so as to
anticipate and plan for capital
expenditures relating to maintenance.
3. is to update all the files
The Energy equipment notebook should be
changed every time a new kind of
equipment is installed.
The Equipment file should be changed
whenever someone discoveres an improved
way of maintaining annitem on a card.
The Tickler file should be changed to
reflect the actual needs of the facility.
By following this, the time standards and
the maintenance frequencies can be kept
current, and the maintenance plan can be
adapted to each individual facility.
 To maintain some of the
more complex equipment
properly, it is necessary to
have more detail than
Detailed could be presented in
Maintenance Table 14.9.
Devoted to a more
Procedures complete discussion of
boilers, pumps and steam
traps
Boilers
• Money spent in proper boiler maintenance is one of
the best investments a company can make, the
benefits are substantial.
• To gain this benefit requires proper boiler
maintenance, either by your own personnel or by a
boiler service company hired to provide this service
on a regular basis.
• Two warnings must be observed, first, safety
precautions must be known an do bserve all the
 Opportunities for
Maximizing Efficiency are:
Excess O2 in Stack Gas
Excessive Stack Gas
Temperature
Boilers Smoking or Excess CO
Flame Appearance
Record Keeping
Maintenance Actions and
Frequencies
Steam Traps
• A mechanical device used to remove air, carbon dioxide,, and condensed
steam and to prevent steam foam flowing freely into the outside air form
steam distribution systems.
• Main function is to permit the removal of steam condensate from a system
while simulataneously preventing the free escape of steam. Last function,
energy of the steam is kept within the system, and the amount of the live
steam within the facility is controlled.
• Steam traps are not maintained, and tis lack of maintenance can create a
hidden cost and the cost of a steam trap failure is dependent upon the
failure mode, with a strong dependence upon the original design.
 Three Main Failure
Modes:
Problems if Traps
Steam Fails Open
Traps Problems if Traps
Fail Shut
Problems of
Improper Drainage
 Open Buckets Traps,
Troubleshooting and Maintenance
Four Basic Float and Thermostatic Traps,
Types of Steam Troubleshooting and Maintenance
Procedures
Traps –
Disk Traps, Troubleshooting and
Opportunities Maintenance Procedures
for maximizing
Thermostatic Traps,
efficiency Troubleshooting and Maintenance
Open Buckets
Traps, • The operation is characterized by its regular
Troubleshooti opening and closing. This creates a nosie
which can be detected with an industrial
ng and stethoscope.
Maintenance • When a trap is installed, the frequency of
clicking should noted on the body of the trap.
• If frequency changes drastically without
corresponding change in steam pressure, trap
should be taken apart and overhauled. Etc.
• Close the inlet valve for a few minutes to let
condensate build up, then let condensate into
trap and ut should work.
 Float and
Thermostatic • In case no steam flow, the float may have
Traps, developed a leak or have collapsed, or the
Troubleshooting air valve may be plugged.
and • The mechanisim may worn and in nees of
Maintenance replacement.
Procedures • If the trap is blowing live ste, the air hole
may be blocked open because of wear or
by piece of scale or the trap may filled
woth dirt.
• To check , valve off the trap and examine
or remove the trap. And freezing can also
be a problem.
 Disk Traps,
Troubleshoo • The contact area between the disk and its
ting and seat can become the corroded or blocked
and this can cause a problem.
Maintenance • To maintain this trap, first check the
Procedures installation to see if the manufacturer’s
directions have been followed.
• Then, if the installation is correct, valve
off the trap from live steam, remove the
top, and check on the condition of the disk
and its surface.
• Unlike the bucket traps, this trap has no
prime, so losing its prime is not a problem
Thermostati
c Traps, • Depending upon the mounting of the
Troubleshoo trap, dirt and scale may not be a
problem in the outlet.
ting and • If the bellows leaks and fills with
Maintenance condesate, the trap may fail instead and
if the bimetallic strip is used instead of
bellows, corrosion can be a problem.
• Like most other traps, failure can
caused in this trap if scale or dirt gets
between the valve and its seat and also
the dirt screen can get plugged up,
causing the trap to fail closed.
MATERIAL
S
MUCH 1. 2. LIFT
HANDLING ENERGY ELECTRIC
LIFT
TRUCKS,
NON-
IS USED
MAINTENA IN
TRUCKS ELECTRIC
3.
MATERIA
NCE LS
CONVEYOR
SYSTEMS
HANDLIN
G,
PROPER
MAINTEN
Electric Lift Trucks
The general maintenance
principles that apply to an electric
lift truck are:
1. Keep the battery charged.
2. Make sure that all fluid levels
are where they should be.
3. Check the brakes and keep
them working correctly.
4. Inspect the electrical
equipment and keep it
running.
5. Lubricate the truck
accordning to manufacturer’s
specifications.
Lift Trucks, Non -
electric
• The main points to maintain on
a lift truck powered by diesel,
gasoline or LPG are the engine,
the hydraulic system, the
transmission, and the braking
system.
• Batteries are important, but
their care is not as central to the
maintenance of these lift trucks
as it is to the maintenance of
electric powered trucks.
Conveyors Systems
• Convegir belts, in floor
towlines, and similar chain or
belt driven equipment have
three important areas where
proper maintenance can save
energy and money. These are
the ff:
• 1. Conveyor Controls
• 2. Drive Motors and Gears
3. Conveyor Belts and Lines
TRUCK OPERATION
AND MAINTENANCE
Wherever trucks are used , there
are opportunities for saving
energy and money. The three
general rules for achieving these
savings are:
1. match the equipment to the
load
2. keep the equipment turned up
and in good repair
3. turn it off if you do not need to
have it running.
 1. Management Decisions –
The person supervising a
three details company with a vehicle fleet
on the general can have a large impact upon
rules in truck the costs of running that fleet
operation and in at least different areas:
maintenance Matching the Vehicle to the
job
Maintaining the Vehicle Yard
Instituting Fuel
Accountability
Taking advantage of
Bottlenecks
2. Daily Maintenance Practices
• In addition to the general maintenance
practices, daily procedures performed by the
operators can create substantial savings in fuel
and operating costs.
• Mandatory inspection of such safety items such
as Brakes, the Horn , and the lights.
• A Daily Inspection should beade of Tires,
Batteries, Air Horses, Fuel, and Lubricant
3. Operating Practices
• In additon to the daily maintenance check, each operator
can do several other things to decrease the fuel
consumption of his or her vehicle.
• These measures include: Eliminating Unnecessary Idling,
Warming the Engune Correctly, Choosing the Most
Economical Speeds for given a Load, Keeping the
Hydraulic System above Stall Speed, and Keeping the
Cooling Temperature within the Specified Time.
 Electrical Measurements

Light Measurements
MEASURIN
G Pressure Measurements

INSTRUME Stack Gas Analysis

NTS used in Temperature Measurements

Maintenance Velocity and Flow Rate

Measurements
Vibration Meausurement
Electrical • Can be used to assess the condition of
Measure individual items of equipment and to
analyze the energy consumption patterns of

ments •
the entire facility.
Troubleshooting and monitoring of
individual units can be accomplished with
portable Wattmeters, Multimeters,
Recording Ammeter, and Power-Factor
Meters.
• Safety Precautions must be known and
carefully observed in the installation and
use of all equipment, particularly that
involving electricity.
 Light
Measure
• Reducing unnecessary lighting has
psychological impacts that can far exceed
any direct impact one energy
ments consumption.
• It is necessary to have well established
lighting standards and a way to compare
existing conditions against those
standards.
• Industrial Light Meter, this instrument is
designed to measure incident light directly
and can be used to measure reflected light
and light transmittance as well.
Pressure
Measure • If equipment is not operating in its proper
pressure range, it can be damaged or the
equipment it serves can be damaged.
ments • Measuring pressure using portable equipment
requires that the equipment to be measured
be equipped with fitting specifically designed
for pressure-sensing equipment.
• Bourdon Gauge and Diaphragm gauge use for
such fitting place for routine inspection.
• Manometer, this kind of gauge can be
mounted across filter bank to indicate when a
clogged filter is causing pressure to build up.
Stack Gas • Proper maintenance of boilers depend
Analysis heavily on knowledge of stack gas
composition.
• If there’ s too much molecular oxygen, the
boiler is operating inefficiently; if there us
too much CO or too kuch smoke, the boiler is
operating inefficiently and creating an
operating hazard.
• It is important to keep track of Oxygen gas,
CO and smoke.
• Three types of monitoring equipment meet
this needs are: Orsat kits, Permanently
Mounted Meters, ans Smoke Detectors.
Temperature Measurements
• Essentials to energy management and proper maintenance in at least four
situations:
• 1. For comfort
• 2. To determine where heat is leaking from a building
• 3. To define abnormally hit areas in a machine
4. To use in the analysis of boiler operations and industrial operations using
process heat.
• Temperatures in these situations call for instruments such as: Pocket
Thermometers, Infrared Photography, and permanently miunted devices
possibly using Thermocouples.
Velocity and Flow Rate
Measurements
• It is necessary to know the flow rate of some substance, such as, air or
steam, to determine where energy is being used.
• For example, a factory with several buildings and a central steam system
may not be metered so that the steam consumption of each building can be
determined.
• It is generally difficult to estimate the amount of air being moved by a fan
in an air conditioning system without making some measurement of air
velocity.
• Three types of measuring instruments used are Flow Hoods, Pitot Tubes
and Orifice Plates.
Vibration measurements
• Vibration is found in most mechanical devices that
move, and sometimes this noise is helpful, as in the
case of the niise caused by bucket steam trap opening
and closing.
• An increase in vibration of a machine is an indication
that something is going wrong.
• The instruments that can be used to check vibrations,
and this two are particular valve in the maintenance
associated with the energy management: The
 SAVING ENERGY
DOLLARS IN MATERIALS
HANDLING AND STORAGE
• In addition to proper maintennace ,
there are many operating changes
that together can save a large
fraction of materials handling
energy cost.
• These cost savings can be realized
if a systematic approach is
followed: Analyzing Present Energy
Usage, Walk-Through Audit,
Finding and Analyzing
Improvements that Cost Money,
and Monitoring.
Analyzing • Energy is used in three ways in materials handling
present and storage: to move material, to condition spaces
for material and to condition spaces people who

Energy •
are moving or storing material.
Energy used to move materials includes fuel or
electricity for lift trucks, diesel or electricity for
Usage conveyor power, or cranes and electricity for
automatic storage and retrieval systems.
• Energy to condition spaces for materials includes
refrigeration for vegetables, controlled
temperature storage for electric components, etc.
• Energy used to condition spaces for people
includes heating, cooling, and ventilating a
warehouse to make comfortable for persons
working there.
 Walk-
through
Three Walk-Through Audits that are
recommended:
1. Is to performed during working hours in an
audit 2.
attempt to find practices that can be improved.
Is performed when office personnel have left
for the day.
3. Is the 2 A.M audit, performed sometime after
most people have left the building.
• Completion of the three walk-through audits
gives a qualitative survey of the equipment
being used, lighting levels and temperatures
being maintained and some operating
improvements that can be instituted.
 Finding and
Analyzing • Walk-Through Audits can uncover
operating practices that can be
improvement improved, but a different kind of
s that cost analysis is needed to discover
Money possible capital-intensive
improvement.
• This analysis has three parts:
Examination of past Energy Bills,
Use of a Checklist, and Economic
justification of the most promising
improvements.
Monitoring
• Monitoring serves three functions: To evaluate progress, to show which measures
work, and to show which measures do not work.
• The first step in a monitoring program is to choose some measure of energy
consumption to monitor.
• Once, the energy management plan has gone into effect, the next step is to graph
the consumption, month by month, to see whether the program has helped and if
so, how much.
• When this monitoring has shown that a measure is particularly effective, find out
why, and copy its best feautures elsewhere. If a measure did not work, find out
why and make sure that the bad features of it not being duplicated elsewhere.
 Two recent development
that have had a dramatic
impacts on energy
management are:

RECENT
1. Energy Maintenance
DEVELOP Management Systems
MENTS
2. New Sensors and
Monitoring Equipment
Energy Maintenance
Management Systems
• The most recent energy costs
and production data would be
available, broken down as much
as possible into costs by areas or
by product, depending upon the
amount of metering that is
installed.
• Variance reports should be
available on request to use in
comparing actual and projected
energy costs.
 Energy
Maintenance • A complete file of maintenance tasks should
available with the ff. information for each:
Managemen 1. Identification Number of equipment to be
maintained
t systems 2. Maintenance tasks to be performed, w/
instructions and checklist for each task.
3. Frequency of Maintenance
4. Expected Maintenance Duration
5. Skills Needed
6. Equipment neede for fault diagnosis for repair
7. Priority and justification if appropriate
8. Repair parts needed
 Energy Maintenance management
• systems
For each unit of equipment maintained, this file would include the ff:
1. Identification number of equipment to be maintained
2. Date and Time
3. Person in Charge
4. Equipment condition
5. Maintennace task performed
6. Time needed for repair
7. Repair parts used
8. Additional relevant notes
 New Sensors and
Monitoring Equipment
Data Loggers: Recently, inexpensive
battery powered instruments have
become available that record
meausrements over time.
• These date loggers are small, battery
powered devices that are equipped
with a microprocessor, data storage
and sensor.
• Most date loggers utilize turn key
software on a personal computer to
initiate the logger and view the
collected data.
 New
Sensors and Ultrasonic Detectors for Steam Trap
Testing. One classical way to check steam
Monitoring traps was the “screwdriver method” where
technician put one end of the screwdriver on
Equipment the steam trap and the other end in his ear.
• This method has been made more
sophisticated by the use of ultrasonic
detectors- stethoscopes with amplifiers
and monitors
• Can be used to monitor the operation of
steam traps and to detect and localize
steam leaks