William Little Head of Key Accounts - Operations Plant Reliability William Little Head of Key Accounts - Operations An introduction discussing - Why do Maintenance? Highlight factors such as: Reliability – Confidence in the plant and low human interference Efficiency – Getting the best from your asset at all times Health & Safety – Being a low risk and ensuring no failures that could lead to accidents Legal Compliance – Fulfilling the necessary compliance eg F-Gas, Written Scheme of Examination, PSSR etc Uptime/Productivity – Ensuring the plant is available at all times to deliver the necessary cooling demands Environment – Keeping the plant in the best condition to avoid losses that may impact the environment eg refrigerant leaks Corporate and Social responsibility – A demonstration that your business does what is right! All of these are inextricably linked by money, but the investment in maintenance can capitalise in your return in all of them.

Aftercare - Why Maintenance ? There is something that we all maintain, or at least we should…..ourselves! We can draw comparisons between maintaining our refrigeration systems and our body’s. The principle is the same, if you don’t look after it, performance, reliability etc all take a hit.

Aftercare - Why Maintenance ? Some people maintain themselves better than others! Do you think these guys keep themselves well maintained?

Aftercare - Why Maintenance ? We all want the things we spend a lot of money on to last as long as possible – some examples of items almost all of us have.

Aftercare - Why Maintenance ? An introduction discussing - Why do Maintenance? Highlight factors such as: Reliability – Confidence in the plant and low human interference Efficiency – Getting the best from your asset at all times Health & Safety – Being a low risk and ensuring no failures that could lead to accidents Legal Compliance – Fulfilling the necessary compliance eg F-Gas, Written Scheme of Examination, PSSR etc Uptime/Productivity – Ensuring the plant is available at all times to deliver the necessary cooling demands Environment – Keeping the plant in the best condition to avoid losses that may impact the environment eg refrigerant leaks Corporate and Social responsibility – A demonstration that your business does what is right! All of these are inextricably linked by money, but the investment in maintenance can capitalise in your return in all of them.

Life Cycle Costs Cost of replacement or disposal Cost of Maintenance and Service Cost of Utilities (electricity, water, gas, chemicals) The following animation demonstrates what the typical split of capital costs, running costs, maintenance costs and cost of replacement or disposal across the life of a plant. Through the life of a plant, the maintenance costs could be anywhere between 5 to 10 times more than its capital cost and the utilities to run it throughout its life is typically even greater again. By investing more in planned preventative maintenance then the running costs of a plant will be reduced without paying anymore for its purchase and no compromise on its replacement or disposal. This saving could be 5-10% of its total lifecycle cost. Investing even further in a plant focused on its aftercare eg with remote monitoring or asset management can reduce running costs even further. This up front investment in a plant with a better focus on aftercare ultimately means the cost of maintenance will reduce also as it takes less time and effort to look after it. This saving has the potential to be greater than the capital cost of the plant, meaning it would pay for itself across it lifecycle. Cost of Purchase (capital cost)

Biggest Impact Areas HARDWARE CONTROLS & REMOTE MONITORING SYSTEM These are the four biggest areas where good preventative maintenance can have an impact Refrigerants, Hardware, Controls Remote Monitoring CONTROLS & REMOTE MONITORING SYSTEM

Refrigerants Refrigerants are the life blood of the system. Needed in the right proportions to operate effectively and efficiently HFC’s have become very expensive and therefore investing in preventative measures eg fixed equipment or more regular checks help ensure the system maintains its refrigerant charge. Various leak detection methods include: Soapy Bubbles Leak Tec fluids Electronic Refrigerant Leak Detector Ultrasonic Refrigerant Leak Detector Refrigerant Dye Tests with Infra-red light Fixed Refrigerant Leak Detectors Integrated Leak Monitoring through the Control System - Graphical representation of the loss of refrigerant ie drops in suction pressure, increases in compressor running, higher than normal superheats, increased run hours etc

Hardware An outline of the main components that make up a refrigeration system Leading in to where the majority of service calls and additional costs come from when not carrying out good preventative maintenance. Compressors or compressor sets Air cooled condensers Shell & Tube, Plate & Shell or Plate Heat Exchangers Evaporators

Condensers

Head Pressure Control As discharge pressure rises More compressor work required 1K rise = 3% more power Tips: Review condenser setpoints Avoid fixed head pressure (switch to EEV and EC fans) Keep coils clean

Non-Condensables Air entering system collects in condenser Discharge pressure rises More compressor work 1K rise = 3% more power Tips: Check for air regularly A good vacuum is achieved when servicing All moisture is removed

Evaporators – Defrosting Only 15% to 20% efficient Adds heat to the store Can cause steaming and ice Tips: Review existing setup Check frequency Check duration

Cooler Cleaning Evaporators collect dirt and debris 25% less airflow = 18% less cooler capacity 50% less airflow = 39% less cooler capacity Cooler runs for longer = higher running costs Tips: Inspect coolers annually Measure airflow Clean regularly

Air flow – due to dirt or ice Point Before After Improvement 1 0.7 m/s 1.3 m/s 86% 2 0.6 m/s 1.2 m/s 100% 3 1.6 m/s 33% 4 1.4 m/s 1.8 m/s 29% 1 2 3 4

Performance and Remote Monitoring Monitor cooling requirement Benchmark system performance Real time data measurement Compare operation against design Discover shortfalls in performance Correct Measure the improvement Importance of good Aftercare when considering the system controls and monitoring at the design stage As we saw earlier considering maintenance at the design stage has the biggest opportunity to save cost through the life cycle The use of remote monitoring and dashboards to provide comprehensive overviews of site performance is a simple way to stay in touch with plant without spending hours of manpower on site . This system can offer clear and concise information and enable customers to quickly see how efficiently their site is performing. Looking at: 1. Current performance / CoP (£) 2. Actual performance / CoP (£) 3. What’s the gap and how to close it out (Insight’s) 4. How to continually monitor the plant thereafter

Summary Good quality, well maintained equipment should last for decades! Well maintained equipment will reduce breakdowns & running costs A good quality maintenance should be a combination of regular PPMs, inspections and performance monitoring Keep design simple and re-appraise regularly to achieve optimum reliability

Highlights Some of the most advanced teams in the world combine both hands on preparation and engineering with communication, data capture and analysis to give the ultimate performance and results.....

Highlights So why is good maintenance important? I’ll let you decide for yourself.

THANK YOU! Thank You! For further support: T: 0141 6387916 M: 07770 336006 E: wlittle@star-ref.co.uk www: www.star-ref.co.uk THANK YOU!