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Preventive Maintenance _ CFC Recordkeeping

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Preventive Maintenance _ CFC Recordkeeping Powered By Docstoc
					                OVERVIEW
Scheduled Maintenance Program
History
Philosophy
Initiating a Scheduled Maintenance Program
Best Practices

CFC Program
Compliance
Tracking Refrigerants
EPA Leak Detection Requirement
Additional Recordkeeping Requirement
                                            HISTORY
       Centralized Shops with Single Trades               Decentralized Shops/Repair Centers with Multiple
                     (Prior 1986)                                         Trades (1986-2003)


                                                                                    AUX. Main
                      Locksmith                                                       South
                                                                  Specialty
                                                                                                  GF East
                                                                 Maintenance
                                                                      AE
                                                                                                  Campus
                                      Carpenter
    Plumber Shop
                                        Shop



                    Maintenance                              AUX. Main             Maintenance         GF Main
                      Services
                                                               North                 Services           West




     HVAC Shop                       Painter Shop
                                                                                                  GF Main
                                                                  Third Shift GF
                                                                                                    East

                      Electrician                                                  Second Shift
                         Shop                                                         AE/GF




ADVANTAGES:                DISADVANTAGES:               ADVANTAGES:                   DISADVANTAGES:
• Labor force availability • No ownership of building   • Ownership among trades • Expertise of supervisor
• Sharing of knowledge • Lack of customer/supervisor    • Familiarization of building • Service calls took priority of
                             interaction                • Better customer services      PM
                           • Lack of building
                             familiarization
                                 TODAY
               Centralized PM / Decentralized Shops or Repair Centers
                                    (2003-Present)

                                             North Zone
                                                Shop
                             West Zone                         South Zone
                               Shop                               Shop




                        Specialty
                                            Maintenance              East Zone
                       Maintenance
                            AE                Services                 Shop


ADVANTAGES:
• Ownership among                                              Preventive/       DISADVANTAGES:
                             Second Shift                      Scheduled
  trades                        AE/GF                         Maintenance
• Familiarization of                                              Shop           • Labor Separation
                                             Third Shift GF
  building
• Better customer
  services
• Focus on services
  calls and PM
WMU BRONCO PHILOSOPHY
OF PREVENTIVE MAINTENANCE

                    Staff
              Management/Trades




Tools/Equipment               Attitude/Culture
      STAFF MANAGEMENT/TRADES
                        Preventive Maintenance
                            Shop Manager


            Engineering                      Planner/Scheduler




Plumber                 Electrician                   Pipe Fitter

          Maintenance                    Chiller                    Skilled
           Mechanics                  Refrigeration                 Trades
                                                                    Helper
 TOOLS / EQUIPMENT



                               And if all else fails…
   Computerized
   Maintenance
Management Software
                      Laser Alignment
                      Tool




     Gas Flue
   Combustion
     Analyzer
     ATTITUDE / CULTURE




                                     Successful Preventive
                                     Maintenance Practices
“If it ain’t broke, don’t fix it!”
 INITIATING A CENTRALIZED PM PROGRAM


• Inventory of Equipment
• Tagging and Database Entry
• Creating Task Procedures and Frequency
• Percentage of Labor Hours Dedicated to
  Preventive Maintenance
• Checks and Balances
• Constant Program Review
 INITIATING A CENTRALIZED PM PROGRAM


• Inventory of Equipment
• Tagging and Database Entry
• Creating Task Procedures and Frequency
• Percentage of Labor Hours Dedicated to
  Preventive Maintenance
• Checks and Balances
• Constant Program Review
 INITIATING A CENTRALIZED PM PROGRAM


• Inventory of Equipment
• Tagging and Database Entry
• Creating Task Procedures and Frequency
• Percentage of Labor Hours Dedicated to
  Preventive Maintenance
• Checks and Balances
• Constant Program Review
 INITIATING A CENTRALIZED PM PROGRAM


• Inventory of Equipment
• Tagging and Database Entry
• Creating Task Procedures and Frequency
• Percentage of Labor Hours Dedicated to
  Preventive Maintenance
• Checks and Balances
• Constant Program Review
 INITIATING A CENTRALIZED PM PROGRAM


• Inventory of Equipment
• Tagging and Database Entry
• Creating Task Procedures and Frequency
• Percentage of Labor Hours Dedicated to
  Preventive Maintenance
• Checks and Balances
• Constant Program Review
 INITIATING A CENTRALIZED PM PROGRAM


• Inventory of Equipment
• Tagging and Database Entry
• Creating Task Procedures and Frequency
• Percentage of Labor Hours Dedicated to
  Preventive Maintenance
• Checks and Balances
• Constant Program Review
 INITIATING A CENTRALIZED PM PROGRAM


• Inventory of Equipment
• Tagging and Database Entry
• Creating Task Procedures and Frequency
• Percentage of Labor Hours Dedicated to
  Preventive Maintenance
• Checks and Balances
• Constant Program Review
     Inventory of Equipment
• Number of Buildings = 136
• Total Square Footage = 7,804,267


• Number of Equipment Identified ~ 10,763
• Number of PM Work Orders Issued Last Year ~ 11,139 / 25%


• Number of Chillers   ~ 28     /     ~11,000 tons
• Number of Air Handlers      ~ 272     /   ~ 7,000 filter changes
• Number of Steam Traps       ~ 3,775
  TAGGING AND DATABASE ENTRY




 WMU Nomenclature




WMU Equipment Barcode
CREATING TASK PROCEDURES AND FREQUENCY
PERCENTAGE OF LABOR HOURS DEDICATED TO PM




                            Carpenter
                            Carpet/Tile Layer
                            Electrician
                            Environmental Control Person
                            Locksmith
                            Maintenance Roofer
                            Millwright/Maintenance Mech.
                            Pipe fitter
                            Plumber
                            Refrigeration Repair Person
                            Skilled Trade Helper
CHECKS AND BALANCES


          • Dedicated Staff
          • Review Completed
            Work Order
          • Perform Site Visits
CHECKS AND BALANCES


          • Dedicated Staff
          • Review Completed
            Work Order
          • Perform Site Visits
CHECKS AND BALANCES


          • Dedicated Staff
          • Review Completed
            Work Order
          • Perform Site Visits
CHECKS AND BALANCES


          • Dedicated Staff
          • Review Completed
            Work Order
          • Perform Site Visits
            THEORY OF
PREVENTIVE MAINTENANCE EVOLUTION
   PREVENTIVE MAINTENANCE EVOLUTION
Service Call Work Orders vs. Preventive Maintenance Work Orders
      BEST PRACTICES
Eddy Current Testing for Chillers
    BEST PRACTICES
Annual Trap Testing / Repairs
BEST PRACTICES
 Laser Alignment
        BEST PRACTICES
Electrical Switch Gear Thermal Inspection
           BEST PRACTICES
       Maintenance Time Reminder
• Utilizing Building Automation System to issue
  Preventive Maintenance work order based
  on run time.
WMU CFC Program
 “THE NEED TO COMPLY”
                 WMU CFC PROGRAM
                    “RECORDKEEPING”

In 1997, with the introduction of our Computerized
Maintenance Management System (CMMS – TMA),
   we were able to integrate our recordkeeping
          policies into one central system.




    Refrigeration Usage Entry   Refrigeration Sales Entry
 TRACKING REFRIGERATION PURCHASES

• All refrigeration
  cylinders have an
  assigned number.
TRACKING REFRIGERATION USAGE
  TRACKING REFRIGERATION EQUIPMENT

Total Equipment with Refrigeration          ~ 799
Equipment with 50# of Refrigeration or more ~ 44
   EPA LEAK RATE REPAIR REQUIREMENTS

• Comfort Cooling
       • 15% per 12 months
• Process Cooling
       • 35% per 12 months

• 30 days from discovery of
  leak
• Industrial process shutdown
  allows 120 days
            Or
• Retrofit/Retirement within 12
  months of detection

“WMU’s philosophy is to repair
           all leaks”
WMU CFC PROGRAM




 http://www.pp.wmich.edu/ms/pm/cfc.html
    Thank You


 Thank You!
anand.sankey@wmich.edu

				
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