The document discusses challenges in maintaining green buildings and the need for "green maintenance" practices. It outlines current reactive maintenance practices and proposes shifting to predictive maintenance by monitoring equipment health, analyzing energy and water usage, and establishing an online complaint management system. Green maintenance practices include optimizing energy and water usage, educating staff, and exploring renewable energy sources.

1. Living in harmony with Nature
Challenges in Operation & Maintenance
of Green Buildings
Dec 2012
ISHRAE : Acre Serve
Tejwant Navalkar
Executive Director – DFX Systems Pvt Ltd

2. 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

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4. Living in harmony with Nature
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

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• Sustainability
Meeting 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 Management
Implementing 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)

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• Environmental Concern
Responsible 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 Energy
Ensures virtually Zero Global Warming and provides self reliance
from external agencies in meeting its energy needs
• Staff and User Training
Training 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)

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8. 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 cables
Cables connected without
lugs Badly laid cables

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Some Interesting Photos (2/3)
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

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Some Interesting Photos (3/3)
Badly maintained
plumbing pipes
Badly maintained AC
outdoor units on terrace
Open Manhole covers
Badly maintained
Pumping station
Terrace – Dumping PlaceWater logged terrace

11. Living in harmony with Nature
• 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)

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• 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
Current Maintenance Practices (2/3)

13. Living in harmony with Nature
• 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.
Current Maintenance Practices (3/3)

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15. 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

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0
1000
2000
3000
4000
5000
6 8 10 12 14 16 18 20 22 24 2 4
TIME OF DAY
ENERGYkW
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

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• 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

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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 5
Time of Day
EnergykW
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

20. Living in harmony with Nature
Effect of Re-Engineering
0
500
1000
1500
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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 5
Time of Day
EnergykW
P-4
P-3
P-2
P-1
Modified Peak Load
Old Peak Load

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Average Power Consumed for a day : Pharmaceutical Company
Energy Measurements – Case Study

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Energy Measurements – Case Study
Power Consumed by a Compressor for a day : Pharmaceutical Co

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Energy Measurements – Case Study
Thermography of Electric Panel : Processing Lab

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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

26. 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

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Winding Temperature Sensors
Vibration Sensors Current Consumption
Rotation Speed
Data Acquisition & Control System
Equipment Monitored
Computer Workstation
EQUIPMENT HEALTH MONITORING SCHEMATIC
Equipment Health Monitoring

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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

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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

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Tejwant Navalkar : +91-9821411436
tmndfx@dfxsystems.org
Contact Details
DFX Systems Pvt Ltd
Engineering & Renewable Energy Solutions
Your Partner
in
Designing For eXcellence
www.dfxsystems.org
Tel: 91-22-2432 4083
Fax: 91-22-2432 5644

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