Building Service Chapter 3

PSMZA Course Note (Chapter 3)

Ver. 1 (MSH-Jun2013): CC608 Building Services 1

3.0 MAINTENANCE WORKS 3.1 The Meaning of Maintenance Works

Activities of maintenance function could be both repair or replacement activities, which are necessary for an item to reach its acceptable productivity condition and these activities, should be carried out with a minimum possible cost.

British Standard Glossary of terms (3811:1993) defined maintenance as:

“The combination of all technical and administrative actions, including supervision actions, intended to retain an item in, or restore it to, a state in which it can perform a required function. Maintenance is a set of organised activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired”.

What is word-class maintenance works?

“It’s the best “simply do the basics very well. The best also take a proactive approach to the management of maintenance.” – Engineer’s Digest February 2001

Characteristic of world-class maintenance performance

i. Clear Vision and Mission for Maintenance ii. Proactive not Reactive iii. Managed Costs iv. Total Facility Understanding of & Participation in

Maintenance v. Top Management Support

3.1.1 The Basic Concept of Maintenance Works

Maintenance objectives should be consistent with and subordinate to production goals. The relation between maintenance objectives and production goals is reflected in the action of keeping production machines and facilities in the best possible condition.

i. The maintenance objectives Maintenance objectives should be consistent with and subordinate to production goals. The relation between maintenance objectives and production goals is reflected in the action of keeping production machines and facilities in the best possible condition. There were: a. Maximising production or increasing facilities availability at the lowest cost and at

the highest quality and safety standards b. Reducing breakdowns and emergency shutdowns c. Optimising resources utilisation d. Reducing downtime e. Improving spares stock control f. Improving equipment efficiency and reducing scrap rate g. Minimising energy usage h. Optimising the useful life of equipment i. Providing reliable cost and budgetary control j. Identifying and implementing cost reductions



Figure 3.1: Maintenance objectives plant

3.1.2 Developing a Maintenance Plan Schedule One of the most important items in maintenance management is developing a good plan

to guide operations within the district. Districts should develop long range strategies and one-year maintenance work plans to implement those strategies.

The one-year plan should be developed after the respective district maintenance budget has been determined. The plan should be a result of analyzing historical quantities of work performed and the resulting level of service. Information on quantities of work may be found in the Maintenance Management Information System reports.

Activities of maintenance function could be either repair or replacement activities, which are necessary for an item to reach its acceptable productivity condition or these activities, should be carried out with a minimum possible cost.

i. Plan Format The format of the plan can be tailored to fit the district; however, the following items should be considered: a. Construction - No major maintenance should be planned on sections of roads

programmed for construction or reconstruction. b. Rehabilitation or Resurfacing - Maintenance needed to prepare roads scheduled

for rehabilitation and/or preventive maintenance should be determined and planned. Work such as base repairs, milling and inlay, edge repairs and blade level ups should be performed in advance to insure proper curing and performance analysis before resurfacing.

c. Special Priority Items - Items that have been given special priority or emphasis by the Administration, Division or District should be planned. Examples include: Sign upgrade program Safety upgrades (Guardrail extruder terminals, attenuator upgrades, etc.) Bridge joint cleaning and sealing Edge and spot sealing

d. Labor Intensive Activities - These activities should be analyzed to determine if

more cost effective measures can be performed. For example, a road that has a large amount of edge raveling or failures should be patched and then edge sealed. The edge seal is a preventive measure that will reduce future labor intensive patching.

e. Section Plans - The maintenance plan should start at the maintenance section level and then can be compiled to determine the district plan.

f. The following illustration shows how the maintenance checklist may be formatted.



Figure 3.2: Sample maintenance checklist



ii. Maintenance Works Categorized Generally the maintenance works were categorized into two areas: a. Planned maintenance

Preventive Maintenance (PM) Corrective Maintenance (CM) Improvement Maintenance (IM) Predictive Maintenance (PDM)

b. Unplanned maintenance

Emergency maintenance Run to Failure/Breakdown Maintenance (RTF)

All this maintenance categories may be performed with state forces or by

contract; however, most preventive and major maintenance work should be contracted. The following definitions of maintenance activities should be used in determining the type of work activity when addressing planning and budgeting.

Example works to be maintenance were contracted work, travel way, shoulder

and side approaches, roadside, drainage, structures, traffic operations, emergency operations.

Figure 3.2: Types of maintenance

3.2 Types of the Maintenance 3.2.1 Preventive Maintenance (PM)

It is a set of activities that are performed on plant equipment, machinery, and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degradation in their operating conditions.

British Standard 3811:1993 Glossary of terms defined preventive maintenance as: “The maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning and the effects limited”.



Preventive maintenance has the following meanings: i. The care and servicing by personnel for the purpose of maintaining equipment and

facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects

ii. Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring.

The advantage of applying preventive maintenance activities is to satisfy most of

maintenance objectives. The summary of this were: i. Reduces break down and thereby down time ii. Lass odd-time repair and reduces over time of crews iii. Greater safety of workers iv. Lower maintenance and repair costs v. Less stand-by equipment and spare parts vi. Better product quality and fewer reworks and scraps vii. Increases plant life viii. Increases chances to get production incentive bonus

The activities PM should be know: i. It is good for those machines and facilities which their failure would cause serious

production losses. ii. Its aim is to maintain machines and facilities in such a condition that breakdowns and

emergency repairs are minimised. iii. Its activities include replacements, adjustments, major overhauls, inspections and

lubrications. iv. Researchers subdivided preventive maintenance into different kinds according to the

nature of its activities: a. Routine maintenance which includes those maintenance activities that is

repetitive and periodic in nature such as lubrication, cleaning, and small adjustment.

Routine maintenance is a procedure to ensure equipment is kept in good condition, and provide a long operating life. Routine maintenance may also discover potential problems, which could cause equipment failure. Sometimes a part is required, but the service provider has forgotten to come back with this part. In which case routine maintenance inspection ensures that: The nature of the problem is properly investigated and documented. If needed, a ‘follow up’ reminder is sent to the service provider. A major part of routine maintenance is just inspection of equipment. This should be done as if seeing the equipment for the first time. At the same time, make note of less understood operation areas, and refer to the operation manual for explanation

b. Running maintenance which includes those maintenance activities that are carried out while the machine or equipment is running and they represent those activities that are performed before the actual preventive maintenance activities take place.

c. Opportunity maintenance which is a set of maintenance activities that are performed on a machine or a facility when an unplanned opportunity exists during the period of performing planned maintenance activities to other machines or facilities.

d. Window maintenance which is a set of activities that are carried out when a

machine or equipment is not required for a definite period of time.



e. Shutdown preventive maintenance, which is a set of preventive maintenance activities that are carried out when the production line is in total stoppage situation.

The factors that affect the efficiency of this type of maintenance: i. The need for an adequate number of staff in the maintenance department in order to

perform this type of maintenance. ii. The right choice of production equipment and machinery that is suitable for the

working environment and that can tolerate the workload of this environment. iii. The required staff qualifications and skills, which can be gained through training. iv. The support and commitment from executive management to the PM programme. v. The proper planning and scheduling of PM programme. vi. The ability to properly apply the PM programme.

Preventive maintenance can be described as maintenance of equipment or systems before fault occurs. It can be divided into two subgroups:

i. Planned maintenance ii. Condition-based maintenance. The main difference of subgroups is determination of maintenance time, or determination

of moment when maintenance should be performed. While preventive maintenance is generally considered to be worthwhile, there are risks such as equipment failure or human error involved when performing preventive maintenance, just as in any maintenance operation.

Preventive maintenance as scheduled overhaul or scheduled replacement provides two of the three proactive failure management policies available to the maintenance engineer. Common methods of determining what Preventive (or other) failure management policies should be applied are, recommendations, requirements of codes and legislation within a jurisdiction, what an "expert" thinks ought to be done, or the maintenance that's already done to similar equipment, and most important measured values and performance indications. To make it simple:

i. Preventive maintenance is conducted to keep equipment working and/or extend the life of the equipment.

ii. Corrective maintenance, sometimes called "repair," is conducted to get equipment working again.

The primary goal of maintenance is to avoid or mitigate the consequences of failure of

equipment. This may be by preventing the failure before it actually occurs which Planned Maintenance and Condition Based Maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail.

Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs.

3.2.3 Corrective Maintenance (CM)

In this type, actions such as repair, replacement, or restore will be carried out after the occurrence of a failure in order to eliminate the source of this failure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms, corrective maintenance is defined as: “The maintenance carried out after recognition and intended to put an item into a state in which it can perform a required function”.

http://en.wikipedia.org/wiki/Time

http://en.wikipedia.org/wiki/Human_reliability



This type of maintenance is subdivided into three types: i. Remedial maintenance, which is a set of activities that are performed to eliminate the

source of failure without interrupting the continuity of the production process. “The way to carry out this type of corrective maintenance is by taking the item to be corrected out of the production line and replacing it with reconditioned item or transferring its workload to its redundancy”.

ii. Deferred maintenance, which is a set of corrective maintenance activities that are not

immediately initiated after the occurrence of a failure but are delayed in such a way that will not affect the production process.

iii. Shutdown corrective maintenance, which is a set of corrective maintenance activities that are performed when the production line is in total stoppage situation.

The main objectives of corrective maintenance are the maximisation of the effectiveness of all critical plant systems, the elimination of breakdowns, the elimination of unnecessary repair, and the reduction of the deviations from optimum operating conditions.

The difference between corrective maintenance and preventive maintenance is that for the corrective maintenance, the failure should occur before any corrective action is taken.

Corrective maintenance is different from run to failure maintenance in that its activities are planned and regularly taken out to keep plant’s machines and equipment in optimum operating condition.

The way to perform corrective maintenance activities is by conducting four important steps:

i. Fault detection ii. Fault isolation iii. Fault elimination iv. Verification of fault elimination

In the fault elimination step several actions could be taken such as adjusting, aligning,

calibrating, reworking, removing, replacing or renovation. Corrective maintenance has several prerequisites in order to be carried out effectively:

i. Accurate identification of incipient problems. ii. Effective planning which depends on the skills of the planners, the availability of well-

developed maintenance database about standard time to repair, a complete repair procedures, and the required labour skills, specific tools, parts and equipment.

iii. Proper repair procedures. iv. Adequate time to repair. v. Verification of repair

3.2.4 Improvement Maintenance (IM)

It aims at reducing or eliminating entirely the need for maintenance.

This type of maintenance is subdivided into three types as follows: i. Design-out maintenance which is a set of activities that are used to eliminate the

cause of maintenance, simplify maintenance tasks, or raise machine performance from the maintenance point of view by redesigning those machines and facilities which are vulnerable to frequent occurrence of failure and their long term repair or replacement cost is very expensive.

ii. Engineering services which include construction and construction modification, removal and installation, and rearrangement of facilities.



iii. Shutdown improvement maintenance, which is a set of improvement maintenance activities that are performed while the production line is in a complete stoppage situation.

3.2.5 Predictive Maintenance (PDM) – Condition based

Predictive maintenance is a set of activities that detect changes in the physical condition of equipment (signs of failure) in order to carry out the appropriate maintenance work for maximising the service life of equipment without increasing the risk of failure.

It is classified into two kinds according to the methods of detecting the signs of failure: i. Condition-based predictive maintenance depends on continuous or periodic condition

monitoring equipment to detect the signs of failure.

ii. Statistical-based predictive maintenance depends on statistical data from the meticulous recording of the stoppages of the in-plant items and components in order to develop models for predicting failures.

The drawback of predictive maintenance is that it depends heavily on information and the

correct interpretation of the information. Some researchers classified predictive maintenance as a type of preventive maintenance.

In predictive maintenance, machinery conditions are periodically monitored and this enables the maintenance crews to take timely actions, such as machine adjustment, repair or overhaul. It makes use of human sense and other sensitive instruments, such as audio gauge, vibration analyser, amplitude meter, pressure, temperature and resistance strain gauges etc. Unusual sounds coming out of rotating equipment predicts a trouble An excessively hot electric cable predicts a trouble. Simple hand touch can point out many unusual equipment conditions and thus predicts a trouble

The main difference between preventive maintenance and predictive maintenance is that predictive maintenance uses monitoring the condition of machines or equipment to determine the actual mean time to failure whereas preventive maintenance depends on industrial average life statistics.

3.2.6 Run to Failure Maintenance (RTF) The required repair, replacement, or restore action performed on a machine or a facility

after the occurrence of a failure in order to bring this machine or facility to at least its minimum acceptable condition.

It is the oldest type of maintenance. It is subdivided into two types: i. Emergency maintenance: it is carried out as fast as possible in order to bring a failed

machine or facility to a safe and operationally efficient condition. ii. Breakdown maintenance: it is performed after the occurrence of an advanced

considered failure for which advanced provision has been made in the form of repair method, spares, materials, labor and equipment.

Disadvantages of RTF i. Its activities are expensive in terms of both direct and indirect cost. ii. Using this type of maintenance, the occurrence of a failure in a component can cause

failures in other components in the same equipment, which leads to low production availability.

iii. Its activities are very difficult to plan and schedule in advance. iv. This type of maintenance is useful in the following situations:

a. The failure of a component in a system is unpredictable. b. The cost of performing run to failure maintenance activities is lower than

performing other activities of other types of maintenance. c. The equipment failure priority is too low in order to include the activities of

preventing it within the planned maintenance budget.



3.3 Maintenance Work Sign



3.4 References Books

Egan M David (1986). The Building Fire Safety Concept. University Technology Malaysia, Skudai.

Fullerton R. L. (1979). Building Construction in Warm Climates. Volume 1, 2, 3. Oxford

University Press, United Kingdom. Hall F. (2000). Building Services & Equipment. Pearson Limited, England. MS EN 81-1:2012. Malaysian Standard. Safety Rules for the Construction and Installation of

Lift- Part1: electric Lifts (first revision). Department of Standards Malaysia. Nor Rizman (2010). Risk Assessment for Demolition Works In Malaysia. Faculy of Civil

Engineering and Earth Resources, Universiti Malaysia Pahang. Undergraduate thesis.

Prashant A/L Tharmarajan (2007(. The Essential Aspects of Fire Safety Management In Hihg-

Rise Buildings. University Teknologi Malaysia. Degree of master science thesis. Riger W. Haines, Douglas C. Hittle (2006). Control System for Heating, Ventilating and Air

Conditioning. Springer-Verlag, New York. Stein, Benjamin, Reynolds, John S., Grondzik, Walter T., and Alison G. Kwok, (2006).

Mechanical and Electrical Equipment for Buildings. 10th ed. Hoboken, New Jersey: John Wiley and Sons, Inc., 2006.

Tan, C. W. and Hiew, B.K., (2004), “Effective Management of Fire Safety in a High-Rise

Building”, Buletin Ingenieur vol. 204, 12-19. Journals N.H. Salleh and A.G. Ahmad. (2009). Fire Safety Management In Heritage Buildings: The

Current Scenario In Malaysia. CIPA Symposium Kyoto Japan. UIAM and USM. Code of Practices Approved Code Of Practice For Demolition: Health And Safety In Employment Act 1992.

Issued And Approved By The Minister Of Labour September 1994. Code of Practice for Lift Works and Escalator Works. (2002 ed). Code Of Practice For Demolition Of Buildings 2004. Published by the Building Department.

Printed by Taiwan Government Logistics Department. Code Of Practice For Demolition Of Buildings (2009). Malaysia Standard Supersede Ms 282

Part 1: 1975. Technical Committee For Construction Practices Under The Supervision Of Construction Industry Development Board, Malaysia.

Demolition Work Code Of Practice (July 2012). Australian Government. Work Health and Safety (Demolition Work Code of Practice) Approval 2012. Australian

Capital Territory. By Dr Chris Bourke, Minister for Industrial Relations.



Others Publishing Coby Frampton. Benchmarking World-class maintenance. CMC Charles Brooks Associates,

Inc. Electrical Installation and Systems (2006). Training Package UEE06. Industry Skills Council,

Australia. Fire Safety Manual (2002). Florida Atlantic University USA. Garis panduan Pendawaian Elektrik di bangunan Kediaman (2008). Suruhanjaya Tenaga

Malaysia. Jabatan Keselamatan Elektrik. Laws of Malaysia. Act 341: Fire Services Act 1988. Publish by The Commissioner Of Law

Revision, Malaysia Under The Authority Of The Revision Of Laws Act 1968 In Collaboration With Percetakan Nasional Malaysia Bhd 2006.

Operations & Maintenance Best Practices: A Guide to Achieving Operational Efficiency.

(August 2010). Release 3.0. Principles of Home Inspection: Air Conditioning and Heat Pumps. (2010). Educational Course

Note. Routine Maintenance Modules. Part II. Uniform Building By Law 1984. (1996). MDC Legal Advisers: MDC Publishers Printers Guidelines For Applicants For A Demolition Licence Issued Under The Occupational Safety

And Health Regulations 1996. Occupational Safety And Health Act 198. The Government of Commerce, Western Autralia.

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Building Service Chapter 3

Engineering

management of maintenance

defined maintenance

maintenance objectives

maintenance plan schedule

wordclass maintenance

year maintenance work

production goals

production machines