PLANNED MAINTENANCE –BEST PRACTICE
Modern Building Maintenance Methods and the Potential to Failure Curve
FM Stream EventRDS Tuesday 6th March 2018
Ronán Potts – Technical Services Manager
CBRE Global Workplace Solutions
Google Ireland Ltd.
Real Estate & Workplace Solutions (REWS)
Mechanical Systems
Electrical Systems
Fabric Systems
Currently 12no. Buildings
7no. In Barrow Street
5no. In Eastpoint
Servicing approx. 120,000m²
◆ Compliance with regulations and legislation
◆ Improved equipment reliability and business continuity
◆ Lower total cost of ownership for key assets
◆ Reduced labour costs - scheduled basis instead of a crash basis to repair breakdowns (e.g. Overtime)
Objective...To avoid the consequence of equipment or system failure as opposed to simply avoiding failure or fixing equipment when it fails.
• Monitor Condition and Predict MaintenancePredictive
Maintenance
• Regular maintenance to mitigate failurePreventative Maintenance
• Wait for it to break down and repair / replaceRun to Fail
(RTF) Maintenance
• Follow on from RTFReactive
Maintenance
What factors dictate the optimum Planned Preventative Maintenance (PPM) Interval for an asset?
Simplified Using Industry Standard;CIBSE Guide M, ASHRAE, SFG-20 (BESA)
P-F Interval of the Asset
Time required to resolve the
cause of failure
Maintenance Cost Vs Failure
Cost
Criticality of asset
What is SFG-20?
• A web-based subscription service
• Building Engineering Services Association -Originally launched in 1990
• Recognised as the industry standard for maintenance specifications
• Growing Library of over 500 scheduleswww.sfg20.co.uk
The Goal of CBM
Pre-empt equipment failure so maintenance can be proactively scheduled when it is needed – and not before.
Predictive –Condition Based Maintenance (CBM)
On Line Monitoring System
Continuous Monitoring increases P-F Interval
Installation Cost Vs Labour + Operational Savings
Predictive Maintenance
Commonly used techniques of condition monitoring:
•Lubricant Sampling and Analysis
•Corrosion Monitoring
•Motor Current Analysis
•Acoustic Emissions Detection (e.g., ultrasound)
•Vibration Measurement and Analysis
•IR Thermography
•Process Parameter Trending e.g., flows, rates,
pressures, temperatures, etc.
•Process Control Instrumentation (measurement
and trending)
•Visual Inspection (look, listen and feel)
CBM Data collection – Two Methods
Spot Readings
Non-critical systems
Portable equipment
Continuous Monitoring
Critical systems
Up to the minute data collection
Intelligent monitoring
systems
CBM – Main Advantages and Disadvantages
Advantages Disadvantages
CBM is performed while the asset is working – online – lower disruption
CBM test equipment and databases are expensive to install
Optimized maintenance intervals Training Costs – Data Analysis and plan execution
Improves worker safety May require asset modifications to retrofit the system with sensors
Reduces the cost of asset failures Condition sensors may not survive in the operating environment
Improves equipment reliability
Minimizes time spent on maintenance
Equipment System Location
Chiller HVAC Building 1 Area 2
FCU HVAC Building 3 Area 1
Transformer Electrical Building 5 Area 2
CHP HVAC & Electrical Building 7 Area 3
Generator Electrical Building 1 Area 4
Condenser HVAC Building 1 Area 2
System Failure Mode
HVAC Loss of conditioned air
Electrical Loss of electrical power
Fire Detection Loss of protection against fire
Leak Detection Loss of protection against leaks
Operators Experienced technicians RCM expertsManufacturersEquipment Records
Failure, mode and effects analysis (FMEA)Failure, mode, effect and criticality analysisHazard and operability studies (HAZOPS)Fault tree analysis (FTA)Risk-based inspection (RBI)
“Does this failure mode have safety implications?”“Does this failure mode result in a full or partial outage of operations?”
Is redesign Technically & Commercially Viable?
Is PPM Technically and Commercially Viable?
Is CBM Technically and Commercially Viable?
Is Equipment Business or Safety Critical?
Y N
CBM PPM REDESIGN RTF
Y N
Y N
Y N
Continuous Review Inputs and Outputs to the System
Are Failure Modes on critical systems still occurring?
Have critical systems been misidentified as non-critical
Have system / location priority changed?
Smart Building Technology:
•Communication Between Building Systems using open Protocol e.g. Modbus, Bacnet
•Facilitates Predictive Maintenance –Analytics used to detect problems and action where required (Alarm)
•Dashboard – single point of monitoring all systems with a building
© 2017 CBRE | CONFIDENTIAL & PROPRIETARY 21 AUGUST 2017
AV Energy Lighting Security BMS
AV NETWORK
ENERGY NETWORK
LIGHTING CONTROL NETWORK
CCTV NETWORK
BMS NETWORK
AV DATA ENERGY DATALIGHTING
CONTROL DATACCTV DATA BMS DATA
AV UI ENERGY UILIGHTING
CONTROL UICCTV UI BMS UI CAD
CAD data
Real Estate
Enterprise Building – Many Siloed Solutions
SPACE ANALYTIC
NETWORK & GATEWAYS
APPLICATION API
DATA LAKE
ENERGY OPTIMIZATION
CBM SYSYTEMS
DEVICES
Converged
IT/OT Network
Any “open”
device - Calls
for industry
standards
Data Lake and
ML, App ready.
Cloud platform
Any system or
application
BOS (Building Operating System) Horizontal Approach
Smart Mapping:
● Locate and track all assets using specialised 3D camera phones / tablets
● Ingest all building information○ BIM○ Generate, asset registers etc
● QR codes● Augmented Reality AR
© 2017 CBRE | CONFIDENTIAL & PROPRIETARY 24 AUGUST 2017
Best Practise in Planned Maintenance Summary –
1. Understand the concept of the P-F Curve
2. Use the P-F Interval to determine optimum service intervals
for preventative maintenance (or industry standard SFG20)
3. Consider predictive maintenance (CBM) strategies where
required and viable
4. Use the reliability centred maintenance (RCM) technique to
determine the optimum maintenance strategy for your
business