Environmental Impact of Maintenance

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

GANDHINAGAR, GUJARATME-ASSIGNMENT 2

Submitted to:

Mr. Manoj TiwariAsst. ProfessorDFT/NIFT Gandhinagar

Submitted By :

Amalendu Sekhar DasSouvik MandalCourse Name: M.FtechSemester: 2nd Session: 2011 – 2013

Submission Date: 12th April, 2012

TOPIC: ENVIRONMENTAL IMPACT ON MAINTENANCE

TABLE OF CONTENTS Introduction Technical Aspect Effect of Contaminants Operational Factors Temperature & Humidity Environmental Impact on some few new technologies Hybrid Technology Biofuel Solar Energy Gasoline Carbon Footprints

The degree of maintenance and maintenance performance both are very much influenced by environmental factors . Wear & Lubrication are one of the primary concerns of the maintenance department. Following two aspects depend upon load, speed & working temperature. The working atmosphere or environment also affects the type of maintenance practice to be adopted.

The Lubrication system of a machine needs proper attention depending upon the environment where the machine is used, deals with the following factors-

Technical requirements of lubrication

Contamination of lubrication

Operational Factors

Temperature & Humidity

INTRODUCTION

Reference: Mishra,R,C; Pathak,K: Maintenance Engineering and Management, Chapter:17

TECHNICAL ASPECTS Lubricants are used to reduce the frictional forces of the

machine parts. Normally lubricants decided based on load and speed of the equipment, sometimes under special condition it also works as coolant and protect the machine or equipment from adverse condition. So the lubricants also need more attention to run equipment properly in good working condition.

Water also used as coolant, but of proper quality or it will damage the system.

e.g. Failure of Car radiator increases during summer rather than winter.

Only good quality lubricant can withstand adverse condition. Sometimes forming stable emulsion in short period, change of viscosity of oil causes operational problems.

e.g. Steel Plant under certain process high temperature – high pressure oil or lubricant used.


7

EFFECT OF

CONTAMINANTSContaminated lubricants reduce the life of the system.

Nature of the contaminants largely depends upon the nature of the product-material and can be classified as:

• Solids- Dirt, Dust, Metal wear particles, Abrasive material, Cotton fluffs etc.

• Liquids- Soluble or Insoluble acidic bodies byproducts of oxidation or combustion of fuels.

• Miscible Liquids- Water contaminants mixed in dilution form with fuel

• Oxidized- Some lubricants oxidized in contact with free air, very common in any working condition.

To over come the problems caused by following contaminants oil/grease/ lubricants must be checked/analyzed at intervals to check the remaining life.


7

OPERATIONAL

FACTORSCertain Operational Factors aff ect the lubricant during working, are

as:

Process Impact

Working Condition

Skill of Operators

Fire Hazard

Process Impact:

Process parameters infl uence the maintenance work signifi cantly. Speed of the machine is an important factor to decide the type of lubricant.

Working Condition:

Good quality lubricants also defeated if the actual working condition are not taken into consideration.

Skill of Operators:

The skills of the operating personnel plays an important role as sudden breaking or stoppage of the machine may cause overheating of the system and deterioration of the lubricants at faster rates. Sometimes in many organization people working with low technical qualifi cation leads to serious lapses, resulting in accidents and damages to machine.

Fire Hazard:

Care should be taken for selecting the right type lubricants/hydraulic oils for fi re-fi ghting equipment to minimize the risk.

7

TEMPERATURE &

HUMIDITYThe selection of lubricants should be carried out proper

consideration of temperature and humidity of the working environment. The environmental factors as Temperature, Humidity, Light etc affects the quality of lubricants even during storage. Therefore lubricant storage must be also designed prevailing temperature and humidity condition.


ENVIRONMENTAL IMPACT ON FEW NEW TECHNOLOGIES

HYBRID TECHNOLOGY

G-CAR

ARE HYBRID CARS GOOD FOR THE ENVIRONMENT?

HYBRID TECHNOLOGY

HYBRIDS CARS use both gasoline and electricity for power. In most hybrids, the car will be powered by electricity while a small, fuel efficient gasoline engine re-charges the batteries. Although the car uses gasoline, the engine that charges the battery is far more efficient than engines that usually power automobiles.

Reference: Are Hybrid Cars Good for the Environment?|eHow.com http://www.ehow.com/about_5283571_hybrid-cars-good environment.html#ixzz1rlRiRK6C

http://www.ehow.com/about_5283571_hybrid-cars-good-environment.html


MAINTENANCE WASTE

Hybrids require maintenance, and that maintenance places a strain on the environment. Engine oil needs to be either pumped and refined. Tires need to be replaced. In many cases, however, the maintenance waste from a hybrid is much lower than with a conventional car. For example, brake designs on the Toyota Prius1 have resulted in people going well over 100,000 miles without brake service. This is because hybrids do not, in fact, have brakes. Slowing and stopping is done by the same electric engine that provides power.

BATTERY DISPOSAL

The more hybrids on the road, the more batteries will be needed. These components are based on nickel-metal hydrides. As a result, more mining will be needed to keep up with supply chain requirements, and mining facilities create significant pollution.

HYBRID TECHNOLOGY

Reference: Are Hybrid Cars Good for the Environment?|eHow.com http://www.ehow.com/about_5283571_hybrid-cars-good environment.html#ixzz1rlRiRK6C1: Toyota Prius: www.toyota.com/prius-hybrid



http://www.toyota.com/prius-hybrid

HYBRIDS ARE HYBRID

The more hybrids there are on the road, the more catalytic converters there are going to be, and these components will continue to produce the same harmful byproducts.

GAS MILEAGE AND REALITY

There is a belief driving a hybrid will use less gas, and this is not so. Federal mileage metrics are always "best" measures, not the kind of practical results that can be expected when driving on a typical road, in a typical town, operating on a typical personal maintenance program.

HYBRID TECHNOLOGY

Reference: Are Hybrid Cars Good for the Environment?|eHow.com http://www.ehow.com/about_5283571_hybrid-cars-good environment.html#ixzz1rlRiRK6C



BIOFUEL

Regarding regular maintenance and repair, biodiesel vehicles are very similar to conventional vehicles—they are basically standard diesel engine vehicles that can burn biodiesel fuel. In fact, biodiesel vehicles are next in line after flex-fuel vehicles (FFVs) regarding their similarity to conventional gasoline-powered cars. However, these cars do have a few more potential maintenance “gotchas” to watch out for:

Reference:1: http://alternativefuels.about.com/od/generalmaintenance/a/biodiesmaint.htm

BIOFUEL

http://alternativefuels.about.com/od/generalmaintenance/a/biodiesmaint.htm

WATCH OUT FOR ALGAEAlgae growth in the fuel tank and lines is a potential problem. Indeed,

it may seem odd at first—how can anything grow and live in diesel fuel—but it is true, especially in warm and humid climates. As it grows and accumulates over the long haul, the algae can clog the fuel filter and prevent fuel flow.

Top Off Your Tank: Keep your fuel level topped off to prevent moisture build-up from condensation in the tank.

Use Algicides.: Added to the fuel to control algae build-up, algicides are vital in hot, humid climates.

Change that Filter Regularly.: Algae will grow in minute concentrations no matter the climate conditions—so keep the fuel filter changed on a regular basis, and it’ll never have a chance to clog.

BIOFUEL



SLUDGESludge tends to be a problem that is mostly limited to older diesels

that have accumulated years and miles. It’s a “blackish” substance similar to algae—though it’s not living. Sludge builds up in the fuel system over time. Basically, it’s “dirt” that settles to the bottom of the fuel tank. While it is generally harmless settled at the bottom of the fuel tank, when biodiesel is added to the mix, the sludge can be loosened and suspended in the fuel, causing the fuel filter to clog more quickly.

Is biodiesel the bad guy here? Not really, actually it’s a good thing—biodiesel acts as a detergent and will eventually clean out most of the sludge that has built up in the fuel system.

Regular Fuel Filter Changes. When first switching to biodiesel in older vehicles, it may be necessary to change the fuel filter more frequently to remove the purged sludge.

BIOFUEL



COLD WINTER STARTING PROBLEM Be mindful of these three issues on your diesel before cold weather

strikes and you’ll eliminate common diesel cold weather starting problems and at the same time help your diesel provide you with safe, reliable travels throughout the most challenging season of the year. The Fuel Itself

Cold weather starting problems, sluggish diesel fuel, the necessity to use anti-gel additives . You’ve probably heard that the biggest problem with running diesels in cold weather is the tendency of the fuel to gel contains some naturally occurring paraffin and as the temperature drops, this paraffin crystallizes and affects the fluidity of the fuel and may cause hard starting and eventually lead to filter plugging. Luckily these problems are fairly easily solved Winterizing diesel fuel is done to maintain the cold weather flow characteristics, and the ratios vary depending upon regional distribution. To effectively use biodiesel in cold climates, it must be mixed with winterized diesel in varying percentages, which, once again, are regionally dependent.

Check that Battery When it’s cold outside, everything is a little more sluggish—the fuel

is cold, the engine oil is thick and even your car’s cranky. Make sure the battery is in good condition.

BIOFUEL



SOLAR ENERGY

We Have the Solution to Solar’s Dirty Little Secret:Solar PV is often hyped as requiring virtually no maintenance. In

fact, PV installations need regular cleanings to maintain optimal performance. The accumulation of dirt on solar panels has a significant, detrimental impact on the performance of solar power systems. Dirt, however, is only part of the problem. PV system operators must also compete with the build-up of dust, tree debris, moss, sap, bugs, bird droppings, water spots, mold and more. It has been documented that even a 16th of an inch layer of dust can decrease efficiency up to 7% and shortens the payback fro solar power . A hydrophobic surface has been proven to greatly reduce the effects of soiling.

If your panels are treated with NOC on SOLAR™, an EEMS by Clarke Clean , your PV system performance will be optimized through sustainable module clarity through a hydrophobic surface. While many factors impact solar power production in solar panels, experts agree that you will lose power when your panels experience soiling. That loss may range as high as 25% in some areas according to the National Renewable Energy laboratory.NOC on SOLAR™ is a special nanotechnology product created for PV module substrates with a long-term hydrophobic effect on glass surfaces. This is not a sealer that forms a film but rather is a modification of the surface on a molecular level to provide a virtually self-cleaning.

SOLAR ENERGY

Reference:1 http://www.clarkeclean.com/v2/index.php?option=com_content&view=article&id=117&Itemid=196

http://www.clarkeclean.com/v2/index.php?option=com_content&view=article&id=117&Itemid=196

GASOLINE

A natural gas or propane powered vehicle, like any other vehicle or piece of equipment, is easier to maintain and repair if you understand how it works and what unusual characteristics it might possess.Natural gas and propane powered vehicles don’t differ much from their gasoline counterparts. The one major difference that affects the maintenance of these vehicles , is the fuel storage and delivery system.The Fuel Tank – The PlumbingPropane is stored in liquid form, and natural gas can be stored either as a liquid or as a gas. But to maintain either fuel in its stored state, it must be held under very high pressure—around the 200-plusPSI range. As the engine runs, the liquid in the tank “boils-off’ into a vapor state in the upper regions of the pressure tank and continually replenishes the drawn-off vapor that is burned in the engine.

Maintenance Tip: Periodic regular inspection of the tank and its attendant plumbing and pressure regulators should be part of the regular maintenance process. Check the operator’s manual: The inspection schedule is mandated by the manufacturer and should be outlined there.

GASOLINE

Reference:1 http://alternativefuels.about.com/od/generalmaintenance/a/gaspropanemaint.htm

http://alternativefuels.about.com/od/generalmaintenance/a/gaspropanemaint.htm

Clean Burning – Clean Engine – Long LifeThe accumulation of unburned fuel, soot and acids are the major contributors to the breakdown of motor oil. It’s not so much that the oil itself “wears out,” rather it’s the depletion of additive packages from the cumulative effects of time and mileage that renders the oil ineffective. When motor oil is kept relatively clean, the anti-oxidants, anti-scuff compounds, viscosity index improvers (and myriad other additives) don’t take such a “lickin,” so they can keep on “tickin.”

Maintenance Tip: Because the oil stays cleaner longer, it’s reasonable to expect longer intervals between oil changes—furthermore, the engines themselves often have a longer service life and reduced maintenance costs. And that means regular service parts that last longer.

GASOLINE

Reference:http://alternativefuels.about.com/od/generalmaintenance/a/gaspropanemaint.htm

http://alternativefuels.about.com/od/generalmaintenance/a/gaspropanemaint.htm

CARBON FOOTPRINTS

MAKE CLEANING AND MAINTENANCE GREENERReduce the environmental impact of in-building operations

such as cleaning, pest management and maintenance by using more environmentally friendly cleaning products and organic -- or eco-sensitive synthetic -- filters for equipment.1

CARBON FOOTPRINTS

Reference:1: 10 Ways to Cut Carbon Emissions in Your Buildings Source: Johnson Controls Inc. September 15, 2010http://www.greenbiz.com/research/tool/2010/09/15/10-ways-cut-carbon-emissions-your-buildings

http://www.johnsoncontrols.com/


http://www.greenbiz.com/research/tool/2010/09/15/10-ways-cut-carbon-emissions-your-buildings

CASE STUDY OF KONE KONE’s environmental responsibility covers the full lifecycle of our

products from design and manufacturing tomaintaining and modernizing the equipment. Our visionfor delivering the best People Flow™ experience requiresconstant improvements in the effi ciency of our solutions, maintenance processes and ways of working. KONE has always believed in developing innovative and energy-effi cient solutions that keep the total cost of ownership low while reducing the overall impact on the environment.

CARBON FOOTPRINTS

Reference:1: 10 Ways to Cut Carbon Emissions in Your Buildings Source: Johnson Controls Inc. September 15, 2010http://www.greenbiz.com/research/tool/2010/09/15/10-ways-cut-carbon-emissions-your-buildings2: http://www.kone.com/countries/en_US/brochures/Documents/KONE-Eco-efficient-Maintenance.pdf

MEMBERSHIPS/ORGANIZATIONS Member, U.S. Green Building Council

– first elevator/escalator company member• Member, Alliance for Sustainable BuiltEnvironments in the United States• Global Level Member, World Business Councilfor Sustainable Development.




http://www.kone.com/countries/en_US/brochures/Documents/KONE-Eco-efficient-Maintenance.pdf

CARBON FOOTPRINTS

Reference: http://www.kone.com/countries/en_US/brochures/Documents/KONE-Eco-efficient-Maintenance.pdf

ECO-EFFICIENCY GOALS {By KONE}To minimize our own environmental

impact, one of KONE’s targets includes reducing our operational carbon footprint by 3% annually for the period of 2011– 2013, utilizing eco- efficient maintenance practices. KONE provides services that help our customers achieve their eco- efficiency goals in every phase of their building’s life cycle.• Regular professional maintenance ensures the most eco- efficient use of your equipment and the longest, cleanest life cycle, with the smallest environmental impact.• KONE Care for Life™ helps customers determine when and how to modernize equipment with thorough inspections of the safety, accessibility, reliability, energy efficiency and appearance of a building’s vertical transportation equipment.ECO-EFFICIENT SOLUTIONS

KONE’s goal is to create a culture of excellence by operating an environmentally friendly, efficient, economical and safemaintenance vehicle fleet using some simple, effective guidelines. These guidelines have resulted in a correspondingreduction in fuel consumption and CO2 emissions.


CARBON FOOTPRINTS

Reference:1: 10 Ways to Cut Carbon Emissions in Your Buildings Source: Johnson Controls Inc. September 15, 2010http://www.greenbiz.com/research/tool/2010/09/15/10-ways-cut-carbon-emissions-your-buildings2: http://www.kone.com/countries/en_US/brochures/Documents/KONE-Eco-efficient-Maintenance.pdf

KONE’S GREEN FLEET • Project O2xgyen launched in 2008 to reduce theCO2 generated by the KONE global fleet• In 2010, KONE achieved a 4.6% reduction invehicle fleet carbon footprint• Switching KONE’s fleet vehicle from an E-150 to aTransit Connect improved fuel efficiency from 11miles per gallon to 18 miles per gallon• Route-planning technology optimizes technicians’driving routes, reducing emissions.

KONE’S DYNAMIC SCHEDULING SYSTEMDynamic Dispatching utilizes • KONE’s Maintenance and Acquisition Planning (MAP) tool which optimizes route planning by taking technicianlocation into account, optimizing response timeand reducing technician travel time• Utilizes wireless technology• Reduces transport distances• Average 2010 travel time was reduced byapproximately one minute per service order in2011; with over 90,000 service calls annually, thisresulted in about 1500 hours less driving time byKONE technicians.



