Innovations in Maintenance Technology

Facility managers with chillers and heat exchangers in their buildings know that a big part of routine maintenance is merely keeping the equipment clean. Cleaning the internal components, cleaning the housing, and even washing down the work area might be a messy and tedious job, but it’s necessary to ensure the proper function of the HVAC system. Clean equipment simply runs better and breaks down less frequently.

Over the years the complexity of HVAC equipment has increased, but many basic maintenance tasks like cleaning haven’t changed very much. Luckily for technicians, the tools needed to perform this work have improved, and dirty jobs like cleaning, pressure washing, or descaling can be completed faster than ever before.

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Mission Critical Cooling: Focus on Data Centers

A 2016 report by the Ponemon Institute studied 63 data centers across the United States and calculated that the average cost of a large data center outage is $740,357. That astounding number probably makes IT professionals and data center maintenance staff a little nervous. No one wants to be the person who made a mistake that cost the company $740,357! Businesses that cannot keep data centers online also lose customers, costing the company even more money. Finally, there is the high price to rebuild their reputation and bring customers back. The pressure to keep data centers up and running has never been so high.

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Can Prescriptive Maintenance (RxM) Make Tube Cleaning More Efficient and Effective?

For industrial plants using water or fire tube boilers, maintenance managers know that boiler shutdowns need to be planned in advance to minimize plant downtime.  When a boiler is cold the plant is not operating at full capacity so the fewer times per year the boiler is offline, the better. Usually what drives the need for a maintenance shutdown is diminished boiler efficiency from fouled tubes. 

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Why Removing Calcite (Limestone) from Landfill Leachate Systems’ Lines Require Specialized Descaling Chemicals

Calcite clogging is a major problem in the industry. This type of scale is typically associated with pipes, heat exchangers or other water handling equipment in general industry but it is also true that landfill channels can also become completely clogged with limescale. Typically the problem is ignored in landfills until it is too late and leachate channel systems become clogged resulting in back-ups of leachate flow. Ignoring the problem when signs of clogging are starting to happen only creates bigger headaches down the road. 

When it comes to cleaning calcite deposits in your leachate lines, there’s no better option than an industrial strength, specialized chemical descaler.  According to Goodway’s Director of Liquid Solutions, Ray Field, “It’s well documented that an inhibited acid descaler is the product of choice in these cases.” The main advantage to a chemical descaler is its ability to permeate throughout the entire leachate collection piping system. Alternatives like high-pressure water jetting may reach inside the first 75 feet of piping, but after that the scale down the channel is so deep that water jetting can’t get to the worst areas of scale. It then becomes a pervasive problem within the entire leachate network in the landfill.

Other alternatives include commodity acids — for example, commodity grade and concentrated sulfuric acid. But this can make a limescale headache even bigger. When adding sulfuric acid to calcite-clogged pipes, you’re going to end up turning your leachate lines into gypsum (or calcium sulfate). That’s a million times worse than even the worst limescale problem!

Power plants (and any associated landfills) provide an additional challenge. Each involve massive amounts of water. What’s more, they share a symbiotic relationship with regard to methane gas. Power plants pay landfills for their methane gas. When their leachate lines become clogged, methane metering from the landfill slowly chokes off — along with the amount of revenue going to the landfill from the power plant. That’s a direct result of letting calcium carbonate build up and going unchecked in a landfill leachate collection system. 

Certain chemical descalers are not only safe, but also dissolve mineral deposits extremely fast. For example, Goodway’s Scalebreak Liquid Descaler is biodegradable and dissolves calcium, lime, rust and other deposits from your systems. This particular descaler can be applied in a variety of environments that contain different materials, including steel, brass, copper, plastic and rubber. Thanks to Goodway’s customizable capabilities, Scalebreak products include special formulas specifically for stainless steel, maritime applications and potable water systems. Goodway also offers alkaline neutralizing crystals which allows lowering descaling acidity to meet your needs.

 Not only will specialized chemical descalers make systems operate more efficiently in the here and now, they will also increase the overall life of your systems with efficient and non-interrupted operation.

In the end, removing calcite from leachate lines requires customizable chemical liquid solutions for descaling — and maybe an aspirin or two if you’ve put it off for a while.

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Smart Technology for Significant Chiller Energy Savings

In the average building, chillers account for between 35 and 50 percent of energy expenditures. Even minor adjustments in chiller efficiency can significantly lower the overall overhead of your business. Chiller efficiency and its relationship to the Internet of Things will be on everyone’s mind this weekend at the AHR Expo 2017 in Las Vegas, NV.

Magnetic bearing chillers are a quantum leap in chiller technology. They can save a single business $4 million over the life of the chiller in energy costs. These new chillers don’t require oil, or mechanical seals and gears. This ensures a far longer lifespan. At the same time, it can dramatically increase efficiency of the chiller. The U.S. Naval Facility in Newport, Rhode Island saw an energy savings of 65 percent when switching over to these new chillers. What’s more, you don’t have to change out the gaskets, bearings or seals. In terms of total cost of ownership and downtime, magnetic bearing chillers are far superior even to the chillers being producers 10-15 years ago.

Fortunately, it’s not necessary to reinvent the wheel to increase the efficiency of your chillers. The Internet of Things automates efficiency with very little upfront cost. Daikin has just released two chillers (one scroll, one screw) capable of natively monitoring energy consumption at the equipment level. This provides facility managers with a robust, streamlined solution to reduce overall energy costs without any headaches.

In fact, 2017 is set to be the year of the smart building. Internet of Things-enabled chillers will play a vital role in keeping building maintenance costs down and reducing environmental impact without skimping on keeping the building cool. What’s more, IoT-enabled chillers take the burden of scheduling maintenance off of the facilities manager. In some cases, the chillers will be able to order their own replacement parts and maintenance equipment before you even know there’s a problem. When off-site maintenance crews show up, they won’t need you to tell them what’s wrong with the chiller. They’ll already have a host of metrics to help them make the right repairs, helping to save you money on man hours and reduce downtime.

While the Internet of Things will provide significant improvements in efficiency, those won’t matter much with dirty chiller tubes. The RAM-PRO-XL Contractor simultaneously cleans your chiller tubes while preventing corrosion after cleaning. You know how quickly your tubes can start oxidizing and corroding during cleaning. The RAM-PRO-XL Contractor Chiller Tube Cleaner’s TubeGuard system makes sure that won’t happen. The tablet-based system uses biodegradable cleaners without sacrificing anything in the way of power.

Combine the latest advancements in connected technology with robust maintenance tools for optimum performance in your chillers. And if you happen to be attending the AHR Expo this year, make sure to check out our exhibit at Central Hall – C4328.

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