Green Manufacturing Summit New Delhi March 17

Transcription

Adopting Green Technologies
th
through
h use off Stainless
St i l
Steel
St l
Pravin Goel
CII – Green Manufacturing Summit
New Delhi
March 17-18, 2011
1
GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
What is Stainless Steel?
• Stainless Steel is an Alloy of
Iron with minimum 10.5 %
Chromium
• Chromium forms a layer of
Oxide which is
– Very Thin
– Passive
– Impervious
I
i
– Self Forming instantly on damage
Passive CrO Film
Stainless
Steel
Rust
Steel / GI
2
Important Properties
3
Stainless Steel Properties
• Aesthetics
• Inherently
I h
tl Corrosion
C
i
Resistant
• Hygienic
H i i
• Versatile
• High
Hi h strength
t
th tto
weight ratio
• Excellent
E
ll t ffabrication
b i ti
properties
• High Cleanability
• Easily
E il weld-able
ld bl
• Excellent impact
resistance
i t
• High temperature
resistance
• Fire resistance
• Cryogenic
C
i properties
ti
• Environment friendly
4
High Resistance to Corrosion
• Suitable even for
environments
like coastal area.
Corrosion map of India
Extremely Severe
Severe
Moderate
Mild
Negligible
5
Fire Resistance
High
Strength at High
Temperature
Minimum
Mi i
structural
t t ld
deformation
f
ti
Retains
half the room
temperature strength at 500°C
500 C
No
painting required, not prone
to fire
Fire testing: Darchem Engineering, NiDI
6
Stainless Steel Applications in
Building and Architecture
7
Chrysler Building, New York
The Art deco Top was
clad with SS in 1930
Still looks gleaming in
marine, urban and
industrial environment
even after 75 years
Manuallyy cleaned only
y
twice since installation
8
Largest Gold LEED Certified Building:
Pittsburgh
g Convention Center
Bare
St i l
Stainless
Steel Roof
9
Reducing Energy
Requirements
Phoenix City Hall
•
Perforated, polished
stainless steel
window shades
•
US$285,000 one-time
capital savings
•
US$200,000 annual
air conditioning
sa ings
savings
10
Ronald Reagan Washington Airport
Terminal Roof
Completed 1997
• Type 304, 0.559 mm thick
• 54 small Bermuda domes 13 m x 13 m
• Dull finish
• Batten Seam landside canopy
11
Pittsburgh International Airport
Pittsburgh International Airport Roof
•
•
•
•
Airy concourse with 80ft radius Barrel roof
Terne-coated (Tin/ Zinc) finish to impart color
316 g
grade SS
Completed in 1992
Source : SS architectural facts
12
Petronas Towers
Kuala Lumpur, Malaysia
Cesar Pelli & Assoc.
Stainless: Type 316
Height: 88 stories
1,483 feet (452 m)
Flat panels:
0.098 in., (2.5 mm),
Cambric finish
Tubular panels:
0.118 in. (3.0 mm),
No 4 polish
No.
13
Railway station roofing
• Resin-coated profiled SS roof (10,000 sqm)
• Koperkhairane railway station, Navi Mumbai
• 60 years life guarantee
• Two more stations also clad in SS
14
Modular Operation Theatre/ Doors
S
Stainless
S
Steel Walls and equipment
OT/ Fire Doors
Source: http://www.cleanroomindiabase.com/products.htm#cr
15
Modular Kitchens in SS
16
Station Infrastructure
Turnstiles, DMRC
Turnstiles, DMRC
Waterloo Station, London
Dividers, DMRC
17
Wear Resistance Properties
Sugar
g Cane Carriers
Sinimbu Mill – Brazil – 2004
Carbon Steel A36
Original = 9,50 mm
3 harvest seasons = 5,50 mm
Stainless 410D
Original = 6,35 mm
3 harvest seasons = 5,98 mm
• Much higher loss in thickness for carbon steel
• Carbon steel with intensive scratch presence due to wear caused by sand in
the process
• Stainless
St i l
410D keeps
k
its
it surface
f
intact
i t t
18
Important Green Properties
•
•
•
•
Aesthetics – No need of Painting VOC reduction
Hygiene – Reduction in pre
pre-treatment
treatment of food/water
High Clean ability – minimum use of water resources
High Strength to Weight Ratio – Lightweight
structures, saves energy (e.g. Railway Wagons)
• Long
L
Maintenance
M i t
Free
F
Life
Lif – Less need of
Replacement.
• Recyclable – 70% off SS iis made
d ffrom recycled
l d scrap.
Reduces Waste Stream. Saves Renewable Resources.
19
Recycling
• Stainless Steel Recycling is
not a theoretical jargon.
j g
• It is a self sustaining process
y g elements –
• The alloying
Nickel, Moly, Chrome and Iron
are expensive and it is
economically cheaper to
recycle.
• More
M
than
th 70% off St
Stainless
i l
steel is made from recycled
scrap
Source: Euro-inox report on Recycling of Stainless Steel
Scrap
Re-melting
20
No Degradation
• Stainless Steel is not consumed, it remains
part of the sustainable closed loop systems.
• Unlike many other engineering materials,
SS is recycled without any degradation
degradation.
Source: Euro-inox report on Recycling of Stainless Steel
21
Green Material – LEED Certification
Recycled Content
>60- 70%
Is it 100% Recyclable
Yes
Does it Provide Long
g life
Yes ((reduces maintenance and disposal
p
frequency)
q
y)
Is construction waste
diverted from landfill
Yes (high scrap value and potential to reuse)
Ca it be sa
Can
salvaged
aged a
and
d
reused during renovation
Yes
es
Is it a low emitting material
Yes (no coating= zero emission)
Can it help improve indoor
air quality
Yes (no VOC
VOC, corrosion resistant
resistant, bacteria removal)
Does it help avoid use of
toxic material
Yes – long lasting termite barriers, minimal roof
runoff
Can it save energy
Yes (sunscreens, roofing)
Can it conserve water
Yes (corrosion and earthquake resistant water lines)
Can it extend life of other
material
Yes (stone and masonry anchors
anchors, fasteners
fasteners, etc)
Source : As reported in ISSF in 2002
22
Stainless Steel in Water
applications
23
Stainless Steel in Water Applications
• Antibacterial and Hygienic: Recommended for Food
products
• Handling of drinking water: Does not change the taste of
the water
• Low Surface roughness (only 0
0.15
15 to 0
0.25
25 μm)
–
–
–
–
Reduces deposits and film formation
Surfaces are smooth, hard and homogenous.
difficult for Bacteria and Fungi to adhere.
deposits are minimal.
• Stainless Steel is not affected by vandalism and graffiti.
• Wear resistant:
– Remarkable for its abrasion and erosion resistance.
Source: EuroInox: The stainless steel lining of drinking water reservoirs –Initial erection and refurbishment
24
Global References
Taipei Financial Center
Petronas Towers, Malaysia
Aurora Residential Towers,
Australia
304 grade SS Press Fitting type piping
To accommodate High Pressures and Vibration.
Fire protection
H t and
Hot
dC
Cold
ld W
Water
t S
Supply
l
Source: High pressure Urban water Distribution Nickel Vol20, number 2, March 2005
25
Extending building life to 200 years
• A new Concept for
Japanese High Rises
• An ‘all-stainless-steel’
piping system aims to
extend the life of residential
high-rises.
According to the report titled 200 Years
Housing Vision, the average apartment
building in Japan lasts only 30 years,
compared with 55 years for American homes
and 77 for English ones
ones. The short lifespan is
an economic burden for residents as well as
a hindrance to conservation efforts.
Source: www.nickelmagazine.org/apartments
26
Global References
• Lightweight bridges are used to
carry potable water and
pedestrians across river spans
up to 632 m in Japan
• 85% Type 304
• 10% Type 316
• Some 2205 near the coast
• No repainting
• 40% cheaper
p over 30 yyears
• First one built: 1983
• Max pipe diameter: 0.8 m
Lightweight Bridge to carry drinking water in Tokyo.
• There are now ~3000 such
bridges in Japan
Source: Peter Cutler, NiDI, JSSA, Nickel Magazine Mar2005
27
Mettur Dam, Tamil Nadu
•
•
•
•
•
•
Raw water handing in Mettur Dam,
Cauvery River
Fi t stainless
First
t i l
steel
t l raw water
t pipe
i in
i
India (1998)
Lightweight meant easy installation in
hill country
hilly
t
>50 year life expected (2 replacements of cast iron in that time)
Smooth bore meant sustained low
pumping costs
LCC analysis: 60% saving over 50
years
Source: Peter Cutler, NiDI
28
Salt Spray Test Comparison
In Salt spray Test Chloride concentration specified (3%)is hundred times more
than in drinking water (0.025%) and even more than in Sea Water (1.8%)
Source: Salt Spray Test and its use in ranking stainless steel- ISSF, May 2008
29
Applications in Hospitals
As per "Scottish Health Technical Memorandum 04-01:"
11.8 The materials generally used for the conveyance
of water in healthcare premises are stainless steel or
plastics. Copper is only used in exceptional
circumstances such as, an extension to existing
premises with short life expectancy, or very small stand
alone premises.
Erosion in
Copper Pipes
System can be pressure tested up to 25 Bar
Source: Bright Future for SS Plumbing, Association of Plumbing and Heating contractors
30
Effect of water velocity on corrosion rate
0.018
Corros
sion rate (mpy)
Copper
0.015
0.012
0.009
Mild steel
0.006
0.003
Stainless steel
0
0
4
8
12 16 20 24
Fl
Flow
rate (ft/sec)
(f /
)
28
32
31
1522
Differences between traditional materials and
stainless steels in potable water
Water
contamination
Velocity
Water chemistry
Durability
Steel, iron
copper
pp alloys
y
Stainless steel
Fe, Cu, Pb, Zn
Almost nil after
system
stabilises
t bili
< 2 m/sec
Up to 40 m/sec
Limited
Unlimited within
range of potable
waters
20 – 40 years
100 years
32
Demolition waste
During operation
During
construction
33
Durability Tests in Japan
34
Why Fire Sprinklers Fail?
Newly constructed HDIL Building on fire
18th Nov, 2010
3 persons Killed
Fire in “Bombay House” Tata group HQs
Feb 09, 2011,
35
Application in Fire Fighting Systems
36
Approvals to use stainless steels
• National approvals in EU Member States will
be replaced by European Acceptance Scheme
• USA:
– specified
ifi d grades
d approved
d ffor public
bli water
t supply
l
without restriction under ANSI/NSF 61
– approved under International Building Code
– approved under International Residential Code
• National approvals in Australia/New Zealand
Zealand,
China, Malaysia
• India .....
37
Plumbing Code – India
• 2008 Uniform Plumbing Code – India
– Page No.
No 119,
119 Clause 605
605.11
11
– Galvanised Iron:
• Water
W t Pipes
Pi
& Fittings
Fitti
made
d off galvanised
l
i d
iron shall not be recommended in piping
systems used to convey potable water
38
SS Press Fit Product
• Pipe – SS Grade (AISI 304 grade)
• Fittings – Innovative Press Fit Design (AISI
304 grade)
– Sealing Ring
:CIIR/EPDM
• Press
P
fitting
fitti Tools
T l
– Manual / Hydraulic
– Battery Operated
39
Stainless Steel Plumbing System
40
Press Fitting Installation
Installation
Fast, Clean & Safe
Pipe Cutter
Manual Pressing Tool
No Soldering,
No Welding
No Screwing
After Pressing
41
SS Plumbing
• No general corrosion so no need for corrosion
allowance
• No Threading required, hence thinner – 1/3rd the
weight of GI pipe
• No need for protective coating
y suitable for
• No need to control water chemistryboth Soft as well as Hard Waters
• Water purity is maintained
• Lightweight
• Easyy to Install
• Equipment is durable with Low Life Cycle Cost
42
Waste water treatment - LCC
← Old
Huddersfield, UK
Waste water treatment
N
New
↓
• 98% reduction in
maintenance costs
• 25%
% extra p
plant
capacity
43
Easy to install
Indus Hotel, Delhi
Flat in Mumbai
Easy to use in Difficult areas
Time taken :
About 8 hrs against 2-3 days for GI& Copper (1/3rd time).
E
Expected
t d to
t come d
down further
f th to
t 4-5
45h
hrs.
44
Photographs of Installations
AIIMS Expansion
Delhi - House
Gwalior – Heritage Hotel
Commercial - Bakery
Mumbai - Flat
Hotel - Delhi
45
A Big Builder, Mumbai
46
Life Cycle Costs
Cost
• Total Cost
• Average Life
– Repairs
GI
8,000
10 years
SS
14,000
50 years
1 times
Nil
• Cost of Repair (5 times) 10,000
10 000
– Replacement
4 times
• Cost of Replacement
p
60,000
,
• Cost of Interiors
60,000
• Total Lifecycle Costs 138,000
0
Nil
0
0
14,000
47
Life Cycle Cost
(whole of life cost)
Initial Installed Costs
• Materials
• Fabrication
• Installation
+
Costs over the life of the structure
• Maintenance
M i t
• Replacement
R l
t
• Disruption
Di
ti
48
The 1:10:100 Rule
• Cost incurred at various stages
Cost of Design Change
1
10
Cost during Repair
Cost due to Failure/ Accidents
100
49
Summary Comparison
Parameter
Corrosion Resistance
H i
Hygiene
Maintenance Free Life
Enhances Building Life
Strength of Pipes
Ease of Installation
Earthquake Proof
Cleanability
Food Grade
High temperature Application
Low Temperature Application
Fire Resistant
Experience of Usage
Outside Painting Required
Deposition of Algae
Blockage Problem
Damage due to Drilling
High Flow Rate of Water
Low Roughness (less scaling)
Usage in Public Building
Wear Resistant
Joint Assurance System
Saves Pumping Energy
Water Quality affect
Pressure Rating
g
Joint Strength
Application Range
Less conduiting (Jhiri) reqmt
High Wall Strength
Saving in Labor Cost
Saving in Installation Time
Application in High Rise Buildings
Cost
Low Diameter possible
Life Cycle cost
Total 5 *
GI
*
*
*
*
****
**
***
*
*
***
***
****
5*
*
**
*
****
**
*
*
*
***
*
*
***
**
***
**
***
*
*
***
***
*
*
1
PPR
5*
***
***
***
**
**
**
**
**
*
*
*
*
****
*
**
**
***
***
*
*
*
***
****
**
*
**
*
*
****
***
**
5*
*
***
2
cPVC Copper SS Remarks
****
5*
5* 304 Grade SS
***
****
5* Recommended for Food and Pharma equipment
**
***
5* No need of replacement
***
****
5* No leakage, hence no damage to building
*
***
5* SS is the strongest Material
***
**
5* Fast installation with Low Skill worker
**
***
5* Withstands the vibrations and shocks due to its ductile nature
**
****
5* No deposit buildup due to smooth surface
**
****
5* Meets all food grade standards
*
****
5* Retains strength at high temperature
*
***
5* Is not brittle at low temperature, unlike plastics or GI
*
***
5* Withstands High temperature.
*
5*
5* Worldwide usage experinence of 30‐40 years
****
****
5* No need of painting
*
***
5* Smooth surface prevents algae buildup
**
****
5* No deposit buildup hence no blockage
*
****
5* Strongest material doesn't get damaged due to drilling
***
***
5* Smooth and Wear resistant at High Flow rate
***
****
5* Smooth surface prevents deposition
p
p
*
**
5* Strong material not easily damaged
*
*
5* Not effected by sand or high flow rate
*
**
5* No Welding or Solution joining. Permanent Mechanical Joint
***
****
5* Smooth surface need less electricity
****
****
5* No change in water quality during storage
*
***
5* Highest
Highest pressure rating of 25 bar
pressure rating of 5 bar
*
**
5* Press fit joint has foolproof and high strength joint
**
****
5* Used for Air, Water and Many Gases
*
***
5* As Pipe dia is less
*
***
5* Less Brick cutting for piping retains its strength
****
**
5* Fast installation with Low Skill worker
***
**
5* Fast to install (approx 1/3rd time of GI piping)
5
Fast to install (approx 1/3rd time of GI piping)
**
****
5* Not affected by Vibration and Maintenance
Scale :
*
** Slightly more than GI and others
5*
*
****
5* High flow rates allow for use of low diameter
***
****
5* Lowest lifecycle cost
2
1
34 Highest Rating in most parameters
GII – Green Manufacturing
Summit, New Delhi March 17-18, 2011
1 Poor, 5- Best
50
Some Major Clients
•
•
•
•
•
•
•
•
•
•
Chennai Airport
Kanshi
a s Ram
a Hospital,
osp ta , Noida
o da
Indus Hotel, Sahadhara
AIIMS, Delhi
Sugdha Hospital,
Hospital Hisar
Jindal Hospital, Hisar
Govind Nursing Home, Hisar
Heritage Hotel, Gwalior
Houses – Punjabi Bagh,
Pitampura,
Farm Houses, Delhi
•
•
•
•
•
•
•
•
•
•
DLF- Magnolia, Golf Course,
Gurgaon
Jindal Guest House, Delhi
Sony Bakery, Delhi
Orbit Flat
Flat, Mumbai
Jalandhar
Chandigarh
P
Panchkula
hk l
Ambala
Haveli, Jalandhar
Pranayam Floors, Gurgaon
51
To Conclude
Two Piers, Progreso, Mexico
1941,
Stainless
Steel bars
• Functioning pier
– Built about 70 years
ago
(1937 1941)
(1937-1941)
– Stainless rebar
• Non-functioning
g
pier
– Built about 35 years
ago
– Carbon steel rebar
1967, Carbon
Steel bars
Photo courtesy of the Nickel Institute
52
For more details please contact
PRAVIN GOEL
+91 98107 06415
JSL Stainless Limited
[email protected]
[email protected]
BLOG: stainlesssystems.blogspot.com
Thank You
53

Green Manufacturing Summit New Delhi March 17

Transcription

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