1. 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.

2. 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.

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

4. 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.

5. 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.

6. 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)

7. 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

8. 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

9. 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

10. Condensers

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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.....

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

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