Energy Reduction Through Improved Maintenance Practices by Kenneth E. Bmnister Library of Congress Cataloging in Publication Data Bannister, Kenneth E., 1955- Energy reduction through improved maintenance practices / by Ken Bannister. 128p. 6 x 9 in. Includes index. ISBN 0-8311-3082-2 1. Factories-Energy conservation. 2. Plant Maintenance. 3. Electric Power-Conservation. I. Title. TJ163.5.F3B36 1998 658.2-DC2 1 98-43882 CIP Industrial Press, Inc. 200 Madison Avenue NewYork, NY 10016-4078 First Edition, 1999 Sponsoring Editor: John Carelo Project Editor: She$ A. Levart Cover Design: Janet Romano Book Design: Jo Harvie Copyright 0 1999 by Industrial Press Inc., New York. Printed in the United States of America. All rights reserved. This book, or any parts thereof, may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the publisher. Printed in the United States of America 10987654321 E nergy Reduction Through Improved Maintenance Prac- tices is composed of nine distinct areas in which ineffective maintenance practices adversely affect energy consumption. The areas discussed are not exhaustive, as far as ineffective mainte- nance practices are concerned, but provide the reader with a starting point from which to evaluate and address in-house maintenance concerns that result in excessive energy consumption. Each of the nine focus areas is detailed in its own chapter using the following divisions: Introduction: This section provides the reader with a brief overview of the chapter topic and sets the parameters for the ensuing material. Operating Fundamentals: This section describes the basic operating fundamentals rel- evant to the featured maintenance effectiveness area. The theory behind how and why the proposed energy reduction strategy or solution works is discussed and explained in easy to understand language. Additional Information: This section provides information such as formulae, selec- tion criteria, standards, guidelines, and other information rele- vant to the topic area. vii Energy Savings: This section provides estimates of potential and typical elec- trical energy savings available when improved maintenance prac- tices are used. A variety of case studies are included. Quick Tips: This section offers handy tips for energy savings which can be implemented for little or no cost. Key words: Select words, terms, and concepts used within the chapter are listed under this heading. The reader can find definitions for the key words in the glossary at the end of the ‘book. This book functions as a guide to the maintainer, the facil- ity manager and the engineer by suggesting methods and tools that assist in quickly determining and assessing electrical energy losses. Some of the predictive tools featured are capital purchases and require skilled and trained personnel to operate them. All of the predictive tools featured can be purchased, rented, or utilized in a technical service contract available through local suppliers. Listings of local predictive and condition-based service suppliers can be obtained through the Internet, the local yellow page tele- phone directory, or by contacting your local energy provider(s). Many people have made important contributions to this book. From the outset, Richard Okrasa provided valuable advice and support. Jo Harvie provided invaluable editing and construc- tive criticism throughout the entire process. Finally, many com- panies have graciously provided information, graphical content and support for the project. To each and all of these contributors, my thanks. viii INTRODUCTION T he corporate monthly energy bill has, until recently, rarely been viewed by the maintenance department: the energy bill is often under direct control of the operations manag- er, facility manager, or the accounting manager. The 1980s corpo- ration finally recognized maintenance as an integral part of the production process: through dialog and understanding, the indi- vidual roles of each department has lead to partnerships, team- work and new cooperative initiatives; one of these initiatives allows the maintenance department to share the responsibility and gain recognition for its energy reduction efforts. Friction can be classified as the maintenance department's sin- gle largest enemy. Friction causes heat which in turn causes wear, which directly impacts energy consumption levels; the more that hiction is present in a piece of machinery, the greater the energy requirement to operate the machine. A major responsibility of any maintenance department is to ensure that heating, cooling, and generated power systems (compressed air and steam) are operating at a level no less than the original minimal design efficiency level, and to ensure that losses relating to ineffectiveness and energy waste are under the direct control of maintenance. In this situation, main- tenance retains a direct link to energy use effectiveness and is viewed as a major player in the effective reduction of energy waste. Understanding the direct relationship between maintenance and energy effectiveness is essential when establishing energy reduc- tion initiatives. The following sections provide the reader with insight into how effective maintenance practices can conserve energy. ix X INTRODUCTION Maintenance What is maintenance? Maintenance originates from the word ‘maintain’ meaning ‘to keep in an existing state.’ Equipment and facilities must continue to exist and operate at acceptable levels; otherwise, they risk becoming obsolete and non-competitive. Maintenance is a crucial component of any industry, institution, or facility, Maintenance is the component that allows the industry, institution or ficility to service, or produce, an end product in the manner, and at a level, for which its process was designed. Main- tenance should be viewed as an investment in the corporate well- being and be able to sustain a defined level of quality assurance. Defining PmMm What is RM.? l?M. is an acronym that means different things to different people. EM. is an act in which a maintenance function is performed in a structured manner to optimize the use of the maintained unit, thereby ensuring maximum availability, maxi- mum efficiency, and minimally intrusive maintenance. Figure 1.1 illustrates the various interpretations of the “EM.” acronym. Preventive Maintenance consists of maintenance which is performed in a primarily non-intrusive manner, utilizing the sen- sory modes of sight, smell, touch, and hearing to determine equip- ment deterioration. (Overhauls are not preventive maintenance, but minor adjustments are.) Preventive maintenance includes lubri- cation, adjustment, calibration, and housekeeping. Predictive Maintenance consists of non-intrusive maintenance which incorporates technology to assist in early detection of equip- ment deterioration and potential failure. Productive Maintenance consists of basic non-intrusive main- tenance condition checks which are performed by non-maintenance or production staff. INTRODUCTION xi Figure 1.1 The Meaning of P.M. (Courtesy of Engtech Industries Inc.) Planned Maintenance consists of intrusive maintenance which is performed in a planned manner (labor, tools, and spare parts are at the ready) before equipment failure has occurred. Planned Main- tenance usually results from preventive, predictive, and productive maintenance. Overhauls are an example of planned maintenance. Proactive Maintenance consists of all maintenance, intru- sive and non-intrusive, which is performed in a planned and non-reactive (to breakdown) manner. Profit Maintenance consists of all maintenance which is per- formed with the singular goal of eliminating unnecessary downtime and throughput losses. xii INTRODUCTION Maintenance Practices and Energy Consumption How will good maintenance practices afect energy consump- tion? Maintenance is a business concerned with and dedicated to evaluation, assessment, calibration, adjustment, repair, overhaul and replacement of failed components in machinery, facilities, tools, and mechanical and electrical systems. The majority of equipment consumes a basic level of ener- gy, regardless of its output; this means that specific consumption is a function of load. High efficiency is achieved through three key elements: 1) good energy-efficient design (which is difficult to change without major rework), 2) effective maintenance, and 3) good load factor (i.e., optimum use of machinery in energy management terms). Machinery that consumes energy independent of load con- dition (e.g., when idling) requires the production planning department to address idle time reduction-either through streamlined planning or automated controls. Studies performed by the Research Institute for Energy Economics concluded that over 30% of total energy consumed by machine tools in a single shifi was due to idling during operation break times and non- productive times. Mechanical and electrical equipment require sustained energy in order to produce work. Equation 1.1 shows a simple calcula- tion that relates to all moving equipment. Reduction of energy losses dictates the validity and impor- tance of the maintenance function. wo + El Energy In Work Out Energy Losses Equation 1.1 INTRODUCTION xiii Figure 1.2 Reduced Friction Losses = Profit (Courtesy of Engtech Industries Inc.) Whenever two moving surfaces interact, there is a resultant loss of energy due to frictional heat. Heat is contained by effective lubrication, calibration, and adjustment; when this is not done, high energy losses and weaf will occur and result in equipment fail- ure. Not all cases of heat generation can be contained. For example, processes that rely on heat generation as a component of the process must seek alternative solutions such as heat recovery systems. The purpose of any machine or motive device is to produce work. Design and specification of equipment dictates the form in which work is delivered. For example, a motor delivers work-out in the form of torque and horsepower at a given speed: a com- pressor delivers work-out as compressed air at a specified pressure and volume. The energy consumed to produce work-out will vary in accordance to frictional and distribution losses. Through the minimization of frictional losses and distribution losses (e.g., elim- ination of compressed air leaks, steam leaks) 'work-out' can be xiv INTRODUCTION maximized and energy losses minimized; successful achievement of maximizing work-out and minimizing energy losses relies on com- bining effective maintenance and plant engineering and by ensur- ing that production and maintenance departments harmonize towards this common goal. There are many areas that affect the industrial energy bill: by focusing on conserving energy in these key areas, maintenance is able to influence a positive change on the corporate electrical energy con- sumption bill. The following nine areas have been specifidly chosen because of their direct daily l i it o the maintenance bction. 1. Lubrication 2. Compressed air systems 3. Electrical connectivity 4. Mechanical drive systems 5. Waste heat and cooling recovery 6. Housekeeping 7. P.M. Practices 8. Lighting 9. Steam systems implementing an “Energy Reduction Through Improved Maintenance Practices” Program Ask any successfd change management expert or project manager how to successhlly implement an improvement pro- gram and they will likely describe success as being achieved through carell planning and by adopting a structured or engi- neered approach toward program implementation. Energy manage- ment is similar to any other change initiative. Adopting a seven