adopting green technologies th h f st i l st lthrough use
TRANSCRIPT
Adopting Green Technologies th h f St i l St lthrough use of Stainless Steel
Pravin GoelCII – Green Manufacturing Summit
New DelhiMarch 17-18, 2011
1GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
What is Stainless Steel?
• Stainless Steel is an Alloy of Iron with minimum 10.5 %Iron with minimum 10.5 % Chromium
• Chromium forms a layer ofStainless
Passive CrO Film
• Chromium forms a layer of Oxide which is
Very Thin
Steel
– Very Thin– Passive
I i
Rust
– Impervious– Self Forming instantly on damage
Steel / GI
2GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Important Properties
3GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Stainless Steel Properties
• AestheticsI h tl C i
• High CleanabilityE il ld bl• Inherently Corrosion
ResistantH i i
• Easily weld-able• Excellent impact
i t• Hygienic• Versatile
Hi h t th t
resistance • High temperature
resistance• High strength to weight ratio E ll t f b i ti
resistance • Fire resistance
C i ti• Excellent fabrication properties
• Cryogenic properties • Environment friendly
4GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
High Resistance to Corrosion
• Suitable even for environmentsenvironments like coastal area.
Extremely SevereSevereSevereModerateMildNegligibleCorrosion map of India
5GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Corrosion map of India
Fire ResistanceHigh Strength at High Temperature
Mi i t t l d f tiMinimum structural deformation
Retains half the room temperature strength at 500°Ctemperature strength at 500 C
No painting required, not prone to fire
6GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Fire testing: Darchem Engineering, NiDI
Stainless Steel Applications in Building and ArchitectureBuilding and Architecture
7GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Chrysler Building, New York
The Art deco Top wasThe Art deco Top was clad with SS in 1930
Still looks gleaming inStill looks gleaming in marine, urban and industrial environment even after 75 years
Manually cleaned only y ytwice since installation
8GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Largest Gold LEED Certified Building: Pittsburgh Convention Centerg
Bare St i lStainless 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
10
savings
Ronald Reagan Washington Airport Terminal Roof
Completed 1997
• Type 304, 0.559 mm thick• 54 small Bermuda domes 13 m x 13 m
11GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
• Dull finish• Batten Seam landside canopy
Pittsburgh International AirportPittsburgh International Airport Roof
• Airy concourse with 80ft radius Barrel roof• Terne-coated (Tin/ Zinc) finish to impart color• 316 grade SS
12GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
g• Completed in 1992
Source : SS architectural facts
Petronas TowersKuala Lumpur, Malaysia
Cesar Pelli & Assoc.
Stainless: Type 316Stainless: Type 316Height: 88 stories1,483 feet (452 m)
Flat panels:0.098 in., (2.5 mm),Cambric finishCambric finish
Tubular panels:0.118 in. (3.0 mm), No 4 polishNo. 4 polish
13
Railway station roofing
• Resin-coated profiled SS roof (10,000 sqm) • Koperkhairane railway station, Navi Mumbai • 60 years life guarantee
14GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
60 years life guarantee• Two more stations also clad in SS
Modular Operation Theatre/ Doors
OT/ Fire DoorsS SStainless Steel Walls and equipment
15GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Source: http://www.cleanroomindiabase.com/products.htm#cr
Modular Kitchens in SS
16GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Station Infrastructure
Turnstiles, DMRC
Turnstiles, DMRC
17GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Dividers, DMRCWaterloo Station, London
Wear Resistance PropertiesSugar Cane CarriersSinimbu Mill – Brazil – 2004
g
Stainless 410D Original = 6,35 mm
3 harvest seasons = 5,98 mmCarbon Steel A36 Original = 9,50 mm
3 harvest seasons = 5,50 mm
• Much higher loss in thickness for carbon steel• Carbon steel with intensive scratch presence due to wear caused by sand in
the processSt i l 410D k it f i t t
18GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
• Stainless 410D keeps its surface intact
Important Green Properties
• Aesthetics – No need of Painting VOC reduction
• Hygiene Reduction in pre treatment of food/water• Hygiene – Reduction in pre-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)
L M i t F Lif• Long Maintenance Free Life – Less need of Replacement.
• Recyclable 70% f SS i d f l d• Recyclable – 70% of SS is made from recycled scrap. Reduces Waste Stream. Saves Renewable Resources.
19GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Recycling
• Stainless Steel Recycling is not a theoretical jargon.j g
• It is a self sustaining process• The alloying elements –y g
Nickel, Moly, Chrome and Iron are expensive and it is
Scrap
economically cheaper to recycle.M th 70% f St i l• More than 70% of Stainless steel is made from recycled scrap
20GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
scrapRe-meltingSource: Euro-inox report on Recycling of Stainless Steel
No Degradation
• Stainless Steel is not consumed, it remains part of the sustainable closed loop systems.part of the sustainable closed loop systems.
• Unlike many other engineering materials, SS is recycled without any degradationSS is recycled without any degradation.
21GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Source: Euro-inox report on Recycling of Stainless Steel
Green Material – LEED CertificationRecycled Content >60- 70%Is it 100% Recyclable YesDoes it Provide Long life Yes (reduces maintenance and disposal frequency)g ( p q y)Is construction waste diverted from landfill
Yes (high scrap value and potential to reuse)
Can it be salvaged and YesCa be sa aged a dreused during renovation
es
Is it a low emitting material Yes (no coating= zero emission)Can it help improve indoor Yes (no VOC corrosion resistant bacteria removal)Can it help improve indoor air quality
Yes (no VOC, corrosion 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 Yes (stone and masonry anchors fasteners etc)
22GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Can it extend life of othermaterial
Yes (stone and masonry anchors, fasteners, etc)
Source : As reported in ISSF in 2002
Stainless Steel in Water applicationsapplications
23GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
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 15 to 0 25 μm)• Low Surface roughness (only 0.15 to 0.25 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.Stainless Steel is not affected by vandalism and graffiti.• Wear resistant:
– Remarkable for its abrasion and erosion resistance.
24GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Source: EuroInox: The stainless steel lining of drinking water reservoirs –Initial erection and refurbishment
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 d C ld W t S l
25GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Hot and Cold Water SupplySource: High pressure Urban water Distribution Nickel Vol20, number 2, March 2005
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 residentialextend the life of residential high-rises.
According to the report titled 200 YearsAccording 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 The short lifespan isand 77 for English ones. The short lifespan is an economic burden for residents as well as a hindrance to conservation efforts.
26GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Source: www.nickelmagazine.org/apartments
Global References
• Lightweight bridges are used to carry potable water and pedestrians across river spanspedestrians across river spans up to 632 m in Japan
• 85% Type 304• 10% Type 31610% Type 316• Some 2205 near the coast
• No repainting• 40% cheaper over 30 years
Lightweight Bridge to carry drinking water in Tokyo.
p y• First one built: 1983• Max pipe diameter: 0.8 m• There are now ~3000 such
bridges in Japan
27GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Source: Peter Cutler, NiDI, JSSA, Nickel Magazine Mar2005
Mettur Dam, Tamil Nadu
• Raw water handing in Mettur Dam, Cauvery RiverFi t t i l t l t i i• First stainless steel raw water pipe in India (1998)
• Lightweight meant easy installation in hill thilly country
• >50 year life expected (2 replace-ments of cast iron in that time)
• Smooth bore meant sustained low pumping costs
• LCC analysis: 60% saving over 50 years
28GII – Green Manufacturing Summit, New Delhi March 17-18, 2011Source: Peter Cutler, NiDI
Salt Spray Test Comparison
In Salt spray Test Chloride concentration specified (3%)is hundred times moreIn 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%)
29GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Source: Salt Spray Test and its use in ranking stainless steel- ISSF, May 2008
Applications in HospitalsAs 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.alone premises.
Erosion in Copper Pipes
30GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
System can be pressure tested up to 25 BarSource: Bright Future for SS Plumbing, Association of Plumbing and Heating contractors
Effect of water velocity on corrosion rate
Copper0.018
Copper
(mpy
)
0.012
0.015
Mild steelsion
rate
0.012
0.009
Stainless steel
Cor
ros
0.003
0.006
Stainless steel
Fl (f / )0 4 8 12 16 20
0 32 28 24
31GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Flow rate (ft/sec)
1522
Differences between traditional materials and stainless steels in potable water
Steel, ironcopper alloys Stainless steelpp y
Water contamination Fe, Cu, Pb, Zn
Almost nil after system t bilicontamination stabilises
Velocity < 2 m/sec Up to 40 m/sec
Water chemistry LimitedUnlimited within range of potable
waterswaters
Durability 20 – 40 years 100 years
32GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Demolition wasteDuring operationDuring construction
33GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Durability Tests in Japan
34GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Why Fire Sprinklers Fail?
Newly constructed HDIL Building on fire18th Nov, 2010
3 persons Killed
35GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
3 persons KilledFire in “Bombay House” Tata group HQsFeb 09, 2011,
Application in Fire Fighting Systems
36GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Approvals to use stainless steels
• National approvals in EU Member States will be replaced by European Acceptance Schemebe replaced by European Acceptance Scheme
• USA:ifi d d d f bli t l– specified grades approved for public water supply
without restriction under ANSI/NSF 61– approved under International Building Code– approved under International Building Code– approved under International Residential Code
• National approvals in Australia/New Zealand• National approvals in Australia/New Zealand, China, Malaysia
• India
37GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
• India .....
Plumbing Code – India
• 2008 Uniform Plumbing Code – India– Page No 119 Clause 605 11Page No. 119, Clause 605.11– Galvanised Iron:
W t Pi & Fitti d f l i d• Water Pipes & Fittings made of galvanisediron shall not be recommended in piping systems used to convey potable watersystems used to convey potable water
38GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
SS Press Fit Product
• Pipe – SS Grade (AISI 304 grade)• Fittings Innovative Press Fit Design (AISI• Fittings – Innovative Press Fit Design (AISI
304 grade)Sealing Ring– Sealing Ring :CIIR/EPDM
P fitti T l• Press fitting Tools– Manual / Hydraulic– Battery Operated
39GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Stainless Steel Plumbing System
40GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Press Fitting Installation
InstallationInstallationFast, Clean & Safe
Pipe Cutter Manual Pressing Tool No Soldering, No WeldingNo Screwing
After Pressing
41GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
After Pressing
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• No need to control water chemistry- suitable for y
both Soft as well as Hard Waters• Water purity is maintained• Lightweight• Easy to Install
42GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
y• Equipment is durable with Low Life Cycle Cost
Waste water treatment - LCCHuddersfield, UK
Waste water treatment
← Old
Waste water treatment
• 98% reduction in N maintenance costs
• 25% extra plant
New ↓
% pcapacity
43
Easy to install
Easy to use in Difficult areas
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 t d t d f th t 4 5 h
44GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Expected to come down further to 4-5 hrs.
Photographs of Installations
Gwalior – Heritage HotelAIIMS Expansion Mumbai - Flat
Delhi House Hotel Delhi
45GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Commercial - BakeryDelhi - House Hotel - Delhi
A Big Builder, Mumbai
46GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Life Cycle Costs
Cost GI SS• Total Cost 8,000 14,000• Average Life 10 years 50 years
– Repairs 1 times Nil
Cost of Repair (5 times) 10 000 0• Cost of Repair (5 times) 10,000 0– Replacement 4 times Nil
• Cost of Replacement 60,000 0p ,• Cost of Interiors 60,000 0• Total Lifecycle Costs 138,000 14,000
47GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Life Cycle Cost(whole of life cost)
Initial Installed Costs• Materials • Fabrication • Installation
+• Materials • Fabrication • Installation
Costs over the life of the structureM i t R l t Di ti• Maintenance • Replacement • Disruption
48GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
The 1:10:100 Rule• Cost incurred at various stages
Cost of Design Change
1
Cost during Repair10
Cost due to Failure/ Accidents
100
49GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Summary ComparisonParameter GI PPR cPVC Copper SS RemarksCorrosion Resistance * 5* 5* **** 5* 304 Grade SSH i * *** *** **** 5*Hygiene * *** *** **** 5* Recommended for Food and Pharma equipmentMaintenance Free Life * *** ** *** 5* No need of replacementEnhances Building Life * *** *** **** 5* No leakage, hence no damage to buildingStrength of Pipes **** ** * *** 5* SS is the strongest MaterialEase of Installation ** ** *** ** 5* Fast installation with Low Skill workerEarthquake Proof *** ** ** *** 5* Withstands the vibrations and shocks due to its ductile natureCleanability * ** ** **** 5* No deposit buildup due to smooth surfaceFood Grade * ** ** **** 5* Meets all food grade standardsHigh temperature Application *** * * **** 5* Retains strength at high temperatureLow Temperature Application *** * * *** 5* Is not brittle at low temperature, unlike plastics or GIFire Resistant **** * * *** 5* Withstands High temperature.Experience of Usage 5* * * 5* 5* Worldwide usage experinence of 30‐40 yearsOutside Painting Required * **** **** **** 5* No need of paintingDeposition of Algae ** * * *** 5* Smooth surface prevents algae buildupBlockage Problem * ** ** **** 5* No deposit buildup hence no blockageDamage due to Drilling **** ** * **** 5* Strongest material doesn't get damaged due to drillingHigh Flow Rate of Water ** *** *** *** 5* Smooth and Wear resistant at High Flow rateLow Roughness (less scaling) * *** *** **** 5* Smooth surface prevents depositionp pUsage in Public Building * * * ** 5* Strong material not easily damagedWear Resistant * * * * 5* Not effected by sand or high flow rateJoint Assurance System *** * * ** 5* No Welding or Solution joining. Permanent Mechanical JointSaves Pumping Energy * *** *** **** 5* Smooth surface need less electricityWater Quality affect * **** **** **** 5* No change in water quality during storagePressure Rating *** ** * *** 5* Highest pressure rating of 25 barg Highest pressure rating of 5 barJoint Strength ** * * ** 5* Press fit joint has foolproof and high strength jointApplication Range *** ** ** **** 5* Used for Air, Water and Many GasesLess conduiting (Jhiri) reqmt ** * * *** 5* As Pipe dia is lessHigh Wall Strength *** * * *** 5* Less Brick cutting for piping retains its strengthSaving in Labor Cost * **** **** ** 5* Fast installation with Low Skill workerSaving in Installation Time * *** *** ** 5* Fast to install (approx 1/3rd time of GI piping)
50GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
Saving in Installation Time 5 Fast to install (approx 1/3rd time of GI piping)Application in High Rise Buildings *** ** ** **** 5* Not affected by Vibration and MaintenanceCost *** 5* 5* * ** Slightly more than GI and othersLow Diameter possible * * * **** 5* High flow rates allow for use of low diameterLife Cycle cost * *** *** **** 5* Lowest lifecycle costTotal 5 * 1 2 2 1 34 Highest Rating in most parameters
Scale : 1 Poor, 5- Best
Some Major Clients
• Chennai Airport• Kanshi Ram Hospital, Noida
• DLF- Magnolia, Golf Course, Gurgaona s a osp ta , o da
• Indus Hotel, Sahadhara• AIIMS, Delhi• Sugdha Hospital Hisar
• Jindal Guest House, Delhi• Sony Bakery, Delhi• Orbit Flat Mumbai• Sugdha Hospital, Hisar
• Jindal Hospital, Hisar• Govind Nursing Home, Hisar
Orbit Flat, Mumbai• Jalandhar• Chandigarh
P hk l• Heritage Hotel, Gwalior• Houses – Punjabi Bagh,
Pitampura,
• Panchkula• Ambala• Haveli, Jalandhar
• Farm Houses, Delhi • Pranayam Floors, Gurgaon
51GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
To ConcludeTwo Piers, Progreso, Mexico
• Functioning pier1941,
Stainless Steel barsFunctioning pier
– Built about 70 years ago (1937 1941)(1937-1941)
– Stainless rebar
• Non-functioning 1967, Carbon
Steel barsg
pier– Built about 35 years
agoago– Carbon steel rebar
Photo courtesy of the Nickel Institute
52GII – Green Manufacturing Summit, New Delhi March 17-18, 2011
For more details please contactPRAVIN GOELPRAVIN GOEL
+91 98107 06415JSL Stainless LimitedJSL Stainless Limited
[email protected]@hotmail.com
BLOG: stainlesssystems.blogspot.com
Thank You 53