Table Of ContentEnergy 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
