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

Failure is a process, not an event

Usefulness of the P-F Interval

The longer the P-F Interval the better.

I ≤ (P-F) / 2

Preventative 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)

Predictive Maintenance

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

The Reliability Centred Maintenance (RCM) Strategy

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

THANK YOU

QUESTIONS?