How to Analyze and Communicate Preventive Maintenance Address Now or Pay Later

Transcription

1 How to ANALYZE AND COMMUNICATE PREVENTIVE MAINTENANCE - ADDRESS NOW - OR PAY LATER Tuesday, February 22, 2012, 10:15 a.m. 11:30 a.m. John Poytress Moderator Clovis USD Doug Halverson Presented by Clovis USD Bruce Pickering Hanford Joint Unified High School District Gil Nye Lawrence Nye Anderson Associates Gilbert L. Nye, PE Mechanical Engineer President How to Analyze and Communicate Preventive Maintenance Address Now or Pay Later 1

2 Engineering / Design Important Part of System Maintenance Allow for maintenance consideration Include maintenance personnel early Incorporate suggestions & comments Plumbing and HVAC systems Plumbing Be sure water heater fits through door Mechanical room the right size Plumbing fixture trim to have continuity in manufacture 2

3 System / Equipment Quality Central Plant vs. Package Units You get what you pay for $4000 / ton vs. $6000 / ton Energy factors Package Units Maintenance Issues Lower costs lower quality 15 to 20 year life Equipment access, ground / roof access Filter and compressor maintenance No classroom interruptions 3

4 Central Plant year life Quality equipment Major components in one location Can add Thermal Energy Storage Classroom HVAC Unit Self contained (inside / outside) Split systems Floor / ceiling mounted unit ventilator Vertical air handler 4

5 Central Plant Classroom Unit Unit ventilator - Air delivered from one location - Filter size not standard Vertical air handler - Air distribution from ceiling - Standard filter sizes - Noise level Classroom Unit Maintenance In Classroom Units - Walk to unit - No tools to roof - Oil motors - Change filters 5

6 Central Plant Design Air Cooled vs. Water Cooled Maintenance vs. Energy Locate equipment indoors Mechanical Rooms Pumps, Boilers, Controls Extends equipment life Maintenance friendly 6

7 Cardinal Rules No equipment above ceiling No pneumatic controls Analyzing and Communicating Preventive Maintenance Address now or pay later C.A.S.H. Annual conference February

8 Preventive Maintenance Simplified Maintenance what is it? The process of repairing equipment after failure Dictionary says the work of keeping something in proper condition This implies steps taken to keep equipment or devices from failing Recent studies suggest most facilities do not spend enough to maintain equipment in good working order Most wait for failure then repair or replace Run to Fail 8

9 Types of Preventive Maintenance 1. Run to Fail or Reactive Maintenance >55% 2. Preventive Maintenance 31% 3. Predictive Maintenance 12% 4. Reliability Centered Maintenance 2% The need for Preventive Maintenance It is based on actual or impending failure The ideal is to keep equipment running efficiently for it s design life Nothing lasts forever, equipment has a predefined life expectancy-the useful life period The Bathtub Graph 9

10 Component Failure Rate Run to Fail OR Reactive Maintenance Run it until it breaks No actions taken to maintain equipment Predominant mode of maintenance in US Double edged sword 10

11 Run to Fail Reactive Maintenance ADVANTAGES: Low initial costs Less staff needed Less staff training Run to Fail Reactive Maintenance DISADVANTAGES: Increased costs due to unplanned down time Increased labor costs-overtime or outside repair source Higher repair costs-more major breakdowns Inefficient use of staff resources 11

12 Not the best time to start your PM program Preventive Maintenance Maintenance actions performed at a scheduled time as prescribed by equipment manufacturer or observed break down intervals The purpose is to use manufacturers recommended maintenance intervals to add to the useful life span of the equipment 12

13 Preventive Maintenance ADVANTAGES: Cost effective Increased component life cycle Lower energy costs Estimates of 12%-18% costs savings over Run to Fail Preventive Maintenance DISADVANTAGES: Major failures still likely to occur Labor intensive Includes unneeded maintenance Could cause damage to other components while performing unneeded maintenance 13

14 Preventive Maintenance While not the best maintenance program, it has several advantages over Run to Fail. If maintenance is performed as called for by the manufacturer the equipment s life can be extended as the designer had planned. Changing filters, properly lubricating, and cleanliness will also help save energy dollars. PM will not stop major failures, but will help reduce them. Predictive Maintenance Bases equipment needs on the actual condition of the component instead of a time table. Most catastrophic failures will be avoided. Maintenance can be scheduled to reduce overtime costs and smaller parts inventory is needed. 14

15 Predictive Maintenance ADVANTAGES: Increased component life Corrective actions taken prior to failure Less down time Less part and labor costs Predictive Maintenance Improved worker safety Energy savings 8%-12% savings over Preventive Maintenance program 70%-75% elimination of major breakdowns 15

16 Predictive Maintenance DISADVANTAGES: Increased investment in diagnostic tools and equipment Higher level of staff training Hard to sell, potential savings not readily seen by management Predictive Maintenance A predictive Maintenance program is hard to get off the ground. It is expensive in both labor and equipment. There needs to be a total buy-in and patience on the behalf of management that the desired out come of savings will occur. 16

17 Reliability Centered Maintenance (RCM) All equipment and components in a facility are not of equal importance. Design and operation differ from machine to machine. Failure rates are not equal. RCM takes into consideration that facilities have a limit on what resources can be devoted to equipment maintenance. The challenge is to use these funds and manpower in the most effective way. Reliability Centered Maintenance RCM is essentially a hybrid of the Reactive, Preventative, and Predictive types of maintenance. A common RCM program break down is: < 10% Reactive 25%-35% Preventive 45%-55% Predictive 17

18 Reliability Centered Maintenance ADVANTAGES: Can be the most efficient program Reduces costs by eliminating unneeded repairs and maintenance Minimizes major repair frequency Reliability Centered Maintenance Minimizes probability of sudden failures Allows personnel to focus maintenance on critical equipment Allows facility to match resources with it s needs 18

19 Reliability Centered Maintenance DISADVANTAGES: High startup costs due to more staff training and the need for sophisticated testing equipment Potential of savings not easily seen by management Initiating RCM 1. Develop a master equipment list 2. Prioritize these components based on importance 3. Assign them into logical groupings 4. Determine what kind maintenance work needs to be done and how often using: a. O & M manuals b. Equipment history c. Component failure analysis d. Good engineering judgment 19

20 Initiating RCM 5. Assess the size of your staff 6. Decide what tasks can be performed by your staff 7. What tasks need to be contracted out 8. Identify the most effective maintenance tasks and strategies to implement Summary Run to Fail Machinery runs until it dies No work done to preserve equipment Cost: $18/hp/yr 20

21 Summary Preventive Maintenance Maintenance determined by time intervals Repair or replacement of equipment usually prior to breakdown $13/hp/yr Summary Predictive Maintenance Schedule maintenance when mechanical or operational conditions are indicated Repair or replacement of equipment usually prior to breakdown $9/hp/yr 21

22 Summary Reliability Centered Maintenance Hybrid of previous 3 styles Best Savings Potential $6/hp/yr Clovis Unified Pm Program Use the RCM frame work Created inventory of equipment to be in program Catalogued in computerized work order system Prioritized frequency of PM work 22

23 Clovis Unified Pm Program Decided what PM tasks best benefited each machine Entered information in automated work order system to generate a PM request at the prescribed interval Work completed by technician and logged into our system. 23

24 Clovis Unified Pm Program We also created a PM team and schedule time at every site during the school year 2 days at Elementary sites 5 days at Intermediate and Administrative sites 10 days at Secondary sites Clovis Unified Pm Program A meeting is scheduled with every principal and plant supervisor about 30 days prior to the crew visiting their campus. The following is discussed: All open work orders pending by Maintenance, Grounds, and Custodial Discuss any Deferred Maintenance projects scheduled for the summer Review any additional work that needs to be addressed 24

25 The Double Edged Sword Worst recession in 50 years Clack County Schools-Las Vegas Need $5.1 BILLION to repair and modernize their schools over the next 10 years $3 BILLION is needed for repairs of run down schools They have 357 schools and 35 administrative sites $200 million per year is needed for maintenance Will rise to $260 million if repairs are deferred The Double Edged Sword Clark County School is 5 th largest in the country they spend $1.52 per sq ft on maintenance The 6 th largest district spends $2.68 sq ft Clark has cut their maintenance staff by 25% They spend only 11% of their maintenance budget on PM They are now in the Pay me later mode of PM 25

26 Preventive Maintenance Pay now or Pay later District Stats Three High Schools: Hanford High School, Started in the late eighteen hundreds and most existing buildings were built in the 50s and 70s. Built for 1700 students. The campus is on 65 acres and has 200,000 square feet of buildings. 26

27 Hanford West Built in 1963 & students 55 acres 190,000 square feet Sierra Pacific Built in ,000 square feet 91 acres, includes softball complex Will house 950 students and 1700 when built out. 27

28 Sanity Maintenance is a top priority! Priceless! Filter Changes We change filters at least three times a year on all A/C units. Some units get four or five changes because of their location. We have approximately 900 filters and it costs $25,000 per year. 28

29 Gym Bleachers: $6500 per year Gym Floors Yearly scuff and re-coat, complete sanding Re-finish every ten years. 29

30 Centrifugal Chillers Serviced three times per year Two inspections and one full service. Service includes condenser cleaning and oil samples. $5900 per year. Thermal Storage Chiller Serviced twice a year Service includes condenser cleaning, leak test, trim charge, and lubrication of auxiliary equipment. $1600 All A/C systems are enrolled in the "Savings by Design Program" with SCE. This saves the district $60,000 per year on electricity. 30

31 More Sanity Maintenance Package Units Our Maintenance staff performs the maintenance when they change filters. We stock belts, oil, grease. This works but we need an HVAC person on staff to better maintain systems. 31

32 Fulton Boilers Yearly service includes cleaning, inspection, and replacement of wear parts. Cooling towers are serviced three times a year. We use no chemical treatment. 32

33 Our mowers are maintained by the operators and the Bus Mechanics. Why Preventive Maintenance? Fewer customer complaints Fewer breakdowns Lower energy costs Less Fire Fighting! Lower repair costs 33

34 Why Preventive Maintenance? Peace of Mind Priceless! 34