Session: Technology Is Great, But What if We Can t Manage It? Paul Kistler Naval Facilities Engineering And Expeditionary Warfare Center August 11, 2016 Rhode Island Convention Center Providence, Rhode Island
Why newer technologies are not adopted Lack of awareness Financial Technical Unforeseen Problems Improper Commissioning Unfamiliar Operational Procedures Unfamiliar Routine Maintenance Repairs Of New Technology 2
Unforeseen Problems Magnetic Bearing Chiller Compressors 3
Newport Unforeseen Problems Thermister failed. Thermister was replaced and problem has not recurred. Automatic Expansion Valve not tuned properly. Valve was adjusted and problem has not recurred. San Diego Insulated Gate Bipolar Transistor (IGBT) failed. Problem has not recurred. Power surge damaged one of three compressors. Compressor was replaced. Manufacturer has stated that electronics have been improved since this compressor was installed. Electronics were not sealed sufficiently resulting in moisture damage. Sealing has been improved. Jacksonville None 4
Solutions for Unforeseen Problems Wait. Let some one else take the risk Take the risk and cross your fingers Get buy in from management Review carefully any previous lab or field testing* Submit technology to demonstration program for validation* Robust commissioning plan* Robust warranty* *Recommended 5
Improper Commissioning LED Dimmers 6
Improper Commissioning LED Dimmers 7
Solutions for Improper Commissioning Issues Agree ahead of time how system should perform, be very detailed and specific Have very robust commissioning plan 3 rd party commissioning Have Government representative observe and sign off on each commissioning plan test Have customer present for commissioning If something does not work as previously agreed on, do not accept. Be very persistent. 8
Unfamiliar Operational Procedures Air Handling Unit With Active Humidity Control And Re Heat 9
Solutions to Normal Unfamiliar Operational Procedures Issues Make sure all personnel with access to controls are trained Make sure all new employees are trained, make it part of new employee package Install plaques with operating instructions next to the controls 10
Unfamiliar Routine Maintenance Newer technologies should be more cost effective this includes routine maintenance 11
65 MGB 12
MGB EVERY 3,000 MILES (or every 3 months if 3,000 miles not exceeded). 1. Unscrew the tops of the carburettor dashpots, lift out the damper assembly 'A' in Fig.3 and top up with SAE 20W50 engine oil to within 1/2 inch of the top of the pots (arrowed). Oil the carburettor controls. 2. Fill a grease gun with LM grease or a similar recommended multi purpose grease and thoroughly lubricate the following through the appropriate grease nipple, which should first be wiped clean. Give 3 4 strokes of grease gun to: 1. The front suspension upper and lower swivel pin bush and the lower swivel pin (2 or 3 nipples on each side of the car). See Fig.4. Total no. of nipples to grease 6. 2. The universal joints on the front and rear of the propeller shaft (early cars only) and the sliding joint. Se Fig.5. Total no. of nipples to grease 3. 3. The handbrake cable. See Fig.6. Total no. of nipples to grease 1. 3. Check the level of the hydraulic brake fluid in the clutch and brake master cylinder reservoir and top up if the level has fallen to 1/4 inch or more below the bottom of the filler neck, with Castrol LMA or DOT4 brake fluid. See 'A' and 'B' in Fig.7. 4. Check the steering column clamp bolts for tightness. 5. Adjust the rear brakes, and on the front disc brakes inspect the friction pads for wear. Check the hoses and pipes for loose joints, or leaks or wear. Check the hoses and pipes for loose joints, or leaks or wear caused by the suspension or tyres rubbing against the flexible piping. 6. Wash the bodywork and chromium fittings with clean water and a small amount of dishwashing detergent and clean out the interior. Apply a coat of wax, it will not only beautify but guard against rust formation. * 7. Check that all the lights are functioning correctly and replace blown bulbs as necessary. * 8. Lubricate with SAE 20W50 oil the door hinges, bonnet lock operating mechanism, and the safety catch. 9. Lubricate the boot catch and hinges with SAE 20W50 oil 10. Check the battery cell specific gravity readings, and clean the terminals. 11. Lubricate the dynamo (generator) rear bearing. 12. Examine the fan belt and adjust as necessary for the correct tightness. MGB EVERY 6,000 MILES (or every 6 months if 6,000 miles not exceeded). 1. Run the engine until it has reached its normal working temperature. Then drain the oil from the sump by undoing the drain plug (arrowed in Fig.9). Undo the filter and renew the element (or replace the spin on filter). Refill the sump with 7 1/2 pints of SAE 20W50. 2. Perform all the maintenance tasks listed for the 3,000 mile service. 3. Check the condition of the heater and cooling system hoses and replace as necessary. * 4. Lubricate with engine oil the pivot point of the brake and clutch pedal shafts. * 5. Check the fuel lines and the union joints for leaks and replace defective parts as necessary. * 6. Remove and clean the filters in the carburetters and fuel pump where these are fitted. * 7. Check and adjust the valve rocker clearances. 8. Remove the distributor cap, pull off the rotor arm and apply three drops of engine oil to the head of the large screw in the centre of the distributor. See 'B' in Fig.11. 9. Allow three drops of oil past the cam to the automatic timing mechanism. See 'A' in Fig.11. 10. Lubricate the four sided cam by smearing a faint trace of grease over it. See 'C' in Fig.12. 11. Apply a tiny spot of oil to the moving contact breaker pivot pin. See 'D' in Fig.12. Any excess might get on the points and cause misfiring. 12. Check the condition of the contact breaker points, clean and regap them, and if necessary fit a new set and check the timing and advance and retard mechanism. 13. Check the level of the oil in the gearbox and overdrive unit and replenish as necessary. 14. Remove the combined oil filler and level plug from the rear axle (see Fig.13) and top with Castrol Hypoy (SAE 90 EP). After topping up allow sufficient time for any excess to drain. 15. Adjust the carburetter slow running and tune if necessary. * 16. Examine the exhaust system for holes and leaks and replace defective components as necessary. * 17. Balance the front wheels to eliminate steering vibration as necessary. * 18. Check and adjust the steering 'toe in' of the front wheels. 19. Check the suspension nuts, and the steering nuts for tightness. 20. If wished, change over the tyres to equalise wear and inspect the walls for damage. * 21. Lubricate the washer round the wheelbase spindle with several drops of glycerine. 22. Clean and adjust the sparking plugs. 13
2007 Miata 14
Miata EVERY 7,500 MILES (or every 6 months if 7,500 miles not exceeded). 1. Replace engine oil and filter. 2. Lubricate all locks and hinges 15
Magnetic Bearing Chiller Compressor Maintenance 1.Quarterly tightening of terminal screws (could be done in conjunction with #2 once per year) 2.Annual blowing dust off circuit boards 3.Change capacitors every five years Over 10 years that would be 96 work-hours plus $500 for capacitors. 16
How to ensure proper maintenance of new technologies Magnetic Bearing Chiller Compressor 17
18 How to ensure proper maintenance of new technologies Bring in certified outside technicians Train Government technicians Maintenance contract with certified technicians Write maintenance into ESPC and UESC contracts Make sure PM package is developed in your agency s data base (MAXIMO for Navy) Provide O&M manuals to your PM manager Facility monitor or operator should have O&M manual Make sure public works has spare parts in stock.
Repairs Of New Technology Building occupants complained about being uncomfortable (hot), so the easy solution by the technician was to go above the ceiling and disconnect the damper controllers, and manually open them for full flow of air. Then the chill water controller was completely removed, and the chill water valve was forced open with a strand of wire, allowing 24 hr full flow of chill water. In this case, adding technology to this building did not automatically result in efficient operations it was just the opposite. 19
Black controller boxes removed from zone dampers. 20
"Down Open" Valve forced into down position w/ electrical wire. 100% Chilled Water flow 24 hours/day Chill Water controller removed 21
Solutions to New Technology Repair Issues Bring in certified outside technicians Train Government technicians Repair contract with certified technicians Write repair into ESPC and UESC contracts Do spot checks of repairs Use your meters 22
Paul Kistler P.E. C.E.M. Mechanical Engineer PW61 Energy Management/Program Naval Facilities Engineering and Expeditionary Warfare Center 1100 23rd Ave. Port Hueneme CA 93043 (805) 982 1387 23