Have you implemented Reliability Centered Maintenance (RCM) on HVAC, chillers, or boilers in facilities systems before? I am interested in potential challenges specific to this equipment, such as defining system boundaries, managing lead/lag arrangements, and maintaining systems serving multiple buildings. Previously, I have applied RCM to manufacturing systems with clear failure consequences and easily calculated costs. I would appreciate insights from individuals with experience in government or laboratory environments working with facilities equipment. Thank you for any advice you can provide!
Shelley mentioned the presence of US Coast Guard, US Navy, and General Motors Facilities in the area. What can I assist you with? Additionally, I am following up on the NAVSEA RCM training mentioned in your email for next week. I am currently waiting for details from the program director. - Howard
At this moment, I have a number of inquiries regarding maintenance and reliability practices. Firstly, how should intermittently used but critically important equipment be handled - are they considered hidden failures? Secondly, for systems with lead/lag equipment, what are the recommended schedules or procedures for rotation, and what specific questions should be asked? Additionally, when applying RCM logic, should adjustments be made to the analysis process for systems with redundancy that may result in "no scheduled maintenance" outcomes? Lastly, due to underloaded electrical panels and MCCs affecting IR thermography reports, is there a need to reevaluate the effectiveness of the current IR program and its value? As someone new to this field but tasked with establishing RCM and integrating PdM and PM programs, the unique challenges faced in this setting compared to a traditional manufacturing environment have proven to be quite puzzling. Any assistance or guidance on these matters would be greatly appreciated!
quote: 1. In our operations, there is a considerable amount of equipment that is only used intermittently but can be critical when required. Are these considered hidden failures? Yes, typically the first question in a logic analysis would inquire if the failure is apparent to the operator. If the answer is 'no,' then it is categorized as a hidden failure. However, there may be exceptions depending on the boundaries set. For example, focusing solely on the equipment may make malfunctions obvious to the operator. But if the analysis includes affected components, the failure might not be apparent until needed, making it a hidden failure. quote: 2. Many systems incorporate lead/lag equipment, raising questions about rotation schedules and procedures. What key inquiries should be made? Following the RCM logic, redundancy may lead to a majority of findings suggesting "no scheduled maintenance," which may not seem accurate. Should adjustments be made to the analysis process for these systems? Not necessarily, except ensuring appropriate lubrication and servicing, especially in cycling equipment. quote: 3. Due to the scenarios outlined in questions 1 and 2, our electrical panels and MCCs often lack sufficient load for meaningful IR thermography reports. While we have a well-established IR program for electrical components, concerns arise about the effectiveness of the efforts. Reports frequently show insufficient loading during inspections, casting doubt on the effectiveness of infrared technology. Perhaps motor diagnostics, resistance tests, or voltage drop tests would yield better results. Refer to my article, "Your Maintenance Program Is Effective... Isn't It?" in the inaugural edition of Uptime Magazine on page 32. Contact ReliabilityWeb at tohanlon@reliabilityweb.com if you need a copy of Uptime Magazine. Regards, Howard
I am a new member here and currently pursuing a mechanical engineering undergraduate program. My main focus is on gas compression systems. The theme of my thesis revolves around the implementation of RCM in gas compression systems. I would greatly appreciate any insight, suggestions, or experiences that anyone is willing to share on this topic. Thank you in advance for your contribution.
Dear Shelley, I respectfully disagree with the statements above, but acknowledge that I may not have all the necessary information. The discussion revolves around the classification of equipment failures as hidden or evident. It is essential to clarify that a hidden failure is one that is not immediately obvious to operators under normal circumstances. However, if the loss of function becomes evident as soon as the equipment is used, it should not be considered hidden. In the context of intermittently used equipment, the key factor is whether the failure becomes apparent during regular operations. If the equipment is expected to be used periodically, then the failure would be evident and not hidden. In cases where the equipment is standby or part of a protective system, an additional failure would need to occur for it to be classified as hidden. Understanding the distinction between hidden and evident failures is crucial in Reliability Centered Maintenance (RCM) decision-making. The RCM logic guides the determination of maintenance frequency and challenges traditional practices like fixed maintenance intervals. Ultimately, the focus is on finding the most cost-effective maintenance approach for failures with economic or operational implications. When considering safety or environmental risks, the approach to maintenance may differ significantly. It is important to assess the rationale behind rotating equipment and avoid arbitrary practices like equal distribution of usage. Instead, a careful analysis of failure modes and maintenance costs over time is necessary to establish an optimal maintenance strategy. In conclusion, a thoughtful and informed approach to maintenance planning, guided by RCM principles, can lead to improved equipment reliability and cost efficiency. It is crucial to move away from outdated practices and consider the unique characteristics of each piece of equipment to make informed maintenance decisions.
I've applied RCM on HVAC systems in a government setting, and the main challenge we encountered was initial implementation. It was a somewhat complex system serving multiple buildings, so defining boundaries was indeed tricky. We started by focusing on single units and gradually expanding to wider systems for a more holistic approach. Managing lead/lag arrangements required thoughtful coordination and cooperation from different departments, but with good communication channels, it was manageable. Another unique challenge was maintaining the systems during peak usage, particularly in extreme temperatures. If not adequately planned, maintenance could interrupt service inconveniently. While RCM is more challenging to apply in facilities systems compared to manufacturing, the benefits have been rewarding, especially in improved operational reliability and considerable long-term cost savings.
Yes, I've implemented RCM on HVAC systems and chillers in government buildings before. One challenge you might run into is the complexity of interconnected systems. For example, different zones within a building or among buildings may have different cooling or heating needs at different times, and those needs can affect how the system operates. Another challenge, unique to government facilities, could be the high level of scrutiny and the plethora of regulations. The need for approval from several parties can slow down progress. Utilising a comprehensive RCM software can streamline this process, making it easier to identify potential faults and calculate maintenance costs for various scenarios. Ultimately, meticulous planning and clear communication among relevant parties is key.
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✅ Preventive Maintenance
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Answer: 1. What are some specific challenges when implementing Reliability Centered Maintenance (RCM) on HVAC, chillers, and boilers in facilities systems? - Challenges may include defining system boundaries, managing lead/lag arrangements, and maintaining systems serving multiple buildings.
Answer: - The challenges may vary due to factors like clear failure consequences and easily calculated costs in manufacturing systems compared to the complexities of facilities equipment.
Answer: - Individuals with experience in these settings may provide insights into specific challenges and best practices for applying RCM to HVAC, chillers, and boilers.
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