Table Of Content

MAINTENANCE MANAGER'S STANDARD MANUAL FIFTH EDITION THOMAS A. WESTERKAMP Editor-in-Chief William D. Mahoney, PE Technical Services Ana Varela Brett Crouse Cover Design Robert O. Wright BNi PUBLICATIONS, INC. 990 Park Center Drive Vista, CA 92081 1-888-264-2665 Copyright © 2013 by BNi Publications, Inc. All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. While diligent effort is made to provide reliable, accurate and up-to-date information, neither BNi Publications Inc., nor its authors or editors, can place a guarantee on the correctness of the data or information contained in this book. BNi Publications Inc., and its authors and editors, do hereby disclaim any responsibility or liability in connection with the use of this book or of any data or other information contained therein. ISBN 978-155-701-8106 ii Maintenance Manager’s Standard Manual — Fifth Edition Dedicated to Joyce Maintenance Manager’s Standard Manual — Fifth Edition iii TABLE OF CONTENTS Acknowledgments.................................................................................................................................................................iv What This Manual Will Do For You..................................................................................................................................v About the Author..................................................................................................................................................................viii Preface...................................................................................................................................................................................xix PART I MAINTENANCE MANAGEMENT.....................................................................................................................1 Chapter 1 Maintenance Management Strategy for Optimum Physical Plant Life Cycle................................................1 Leadership.......................................................................................................................................................................2 Six Critical Maintenance Management Principles..........................................................................................................2 How to Prepare a Written Maintenance Management Policy..........................................................................................3 Chapter 2 How to Organize and Staff the Maintenance Department...............................................................................13 How to Choose the Best Form for Your Department......................................................................................................13 How to Choose the Best Structure for Your Maintenance Organization by Using Job Evaluation................................16 How to Manage Contract Maintenance Work.................................................................................................................17 How to Optimize Staffing By Skill with Staffing Modeling...........................................................................................20 How to Prepare Your Own Organization Chart..............................................................................................................20 Chapter 3 Guidelines for Training Maintenance Personnel..............................................................................................23 Selecting Maintenance Personnel....................................................................................................................................23 Developing a Master Training Plan.................................................................................................................................25 Orienting New Employees..............................................................................................................................................26 Safety Training................................................................................................................................................................28 How to Train Managers to Be More Effective................................................................................................................28 Training Maintenance Planners.......................................................................................................................................30 Training Employees in Maintenance Trades...................................................................................................................30 How to Train Maintenance Trade Workers to Service Specific Equipment....................................................................32 Training Maintenance Apprentices.................................................................................................................................32 Multimedia Training.......................................................................................................................................................32 Computer-Based Training...............................................................................................................................................37 Chapter 4 How to Prepare a Workable Maintenance Budget...........................................................................................39 Types of Maintenance Budgets.......................................................................................................................................39 Two Effective Budget Preparation Methods...................................................................................................................40 Organizing for Budget Preparation.................................................................................................................................41 How to Prepare and Use Your Own Budget....................................................................................................................41 How to Bring Your Actual Costs in Line With the Budget.............................................................................................42 How to Use Cost Indexes to Project Future Costs...........................................................................................................44 Using Your CMMS to Track Actual Versus Budget.......................................................................................................45 Life Cycle Costing..........................................................................................................................................................46 Life Cycle Management..................................................................................................................................................46 Chapter 5 How to Set Up and Use Shop Floor Labor Controls.........................................................................................47 How to Obtain Information for Better Control of Maintenance Labor...........................................................................47 Developing a Weekly Maintenance Control Report........................................................................................................48 Preparing Trend Charts to Facilitate Maintenance Staffing............................................................................................48 Preparing a Staffing Model From Trends Data...............................................................................................................53 Chapter 6 How to Calculate Productivity Improvement Costs Versus Savings...............................................................55 How to Calculate Maintenance Labor Costs...................................................................................................................55 How to Use Cost Per Standard Hour to Calculate Savings.............................................................................................57 How to Determine the Base Cost Per Standard Hour......................................................................................................57 Comparing the Base Period to the Current Period to Calculate Savings.........................................................................59 How to Increase the Rate of Savings Generated.............................................................................................................59 Maintenance Manager’s Standard Manual — Fifth Edition ix PART II PLANNING AND SCHEDULING MAINTENANCE WORK..........................................................................63 Chapter 7 Planning Your Routine Repairs..........................................................................................................................63 Unplanned: Don’t Fix It If It Isn’t Broken.......................................................................................................................63 Planned: Don’t Wait Till It Breaks to Fix It....................................................................................................................63 Scoping the Job: How the Planned Maintenance Approach Works.................................................................................64 Typical Planner Job Descriptions....................................................................................................................................67 Job-Planning Audits Ensure Consistency and Accuracy.................................................................................................67 Chapter 8 How to Develop an Effective Work Order System............................................................................................69 How to Use the Work Order Form...................................................................................................................................69 A Six-Step Time Reporting Procedure to Complement the Work Order System............................................................76 When and How to Use a Weekly Work Order.................................................................................................................77 How to Successfully Control In-Process Work Orders....................................................................................................79 How to Use the Job Assignment Board...........................................................................................................................84 How to Use the Daily Maintenance Schedule..................................................................................................................86 Handling the Backlog of Maintenance Requests.............................................................................................................91 Responsibility for Backlog..............................................................................................................................................91 How to Measure and Classify Backlog............................................................................................................................91 Handling Unscheduled Work...........................................................................................................................................91 Handling Scheduled Work...............................................................................................................................................91 How to Use the Backlog to Calculate Workforce Requirements.....................................................................................92 How to Determine Weeks of Backlog for a Given Workforce Size................................................................................93 How to Use the Backlog File...........................................................................................................................................93 Work Order Location Control Using the Backlog File....................................................................................................94 How to Start a Backlog File.............................................................................................................................................94 Chapter 9 Planning for Emergency Maintenance Work....................................................................................................97 Guidelines for Effective Requests for Emergency Service..............................................................................................97 Responding to Emergencies.............................................................................................................................................97 How to Plan for Emergencies..........................................................................................................................................98 Effect of Emergencies on Staffing...................................................................................................................................99 Scheduling Versus Emergencies......................................................................................................................................100 Stocking Material for Emergencies..................................................................................................................................100 Handling Job Interruptions..............................................................................................................................................100 Operation Interruptions and Cost of Emergencies...........................................................................................................101 How to Get Emergencies Under Control.........................................................................................................................101 Using a Computerized Maintenance Management System to Control and Reduce Emergency Maintenance................101 Chapter 10 Planning and Controlling Major Equipment Reengineering and Overhaul Projects..................................103 Preliminary Planning.......................................................................................................................................................103 Three Essential Classes of Information for Preparing Engineering Specifications..........................................................104 12-Step Process for Preparing and Executing Major Overhauls......................................................................................106 Conducting a Prejob Conference to Determine the Scope of the Overhaul Project.........................................................108 Tracking and Controlling Reengineering Projects Using the Computer..........................................................................109 PART III FACILITY SPACE PLANNING, JUSTIFICATION AND CONSTRUCTION.............................................111 Chapter 11 Effective Space Planning for Your Facility......................................................................................................111 Three Main Types of Space Requirements......................................................................................................................111 How to Estimate Space Needs: Modular Space Planning................................................................................................112 Four Ways to Find More Space.......................................................................................................................................112 Chapter 12 How to Justify a New or Expanded Facility Plan............................................................................................115 Why Expand?...................................................................................................................................................................115 An Eight-Step Method to Improve Your Facility Space Use...........................................................................................115 Maintenance Manager’s Standard Manual — Fifth Edition x Chapter 13 Construction Project Planning and Scheduling..............................................................................................121 The Questioning Attitude................................................................................................................................................121 Estimating Project Costs.................................................................................................................................................121 How to Prepare Detailed Specifications..........................................................................................................................123 Seven Key Ingredients of a Successful Project Schedule................................................................................................123 Chapter 14 How to Maintain a Safe and Secure Workplace..............................................................................................127 Safety Considerations in Maintenance Work..................................................................................................................127 How to Evaluate Your Safety Program...........................................................................................................................129 Tips on Maintaining Equipment for Safety.....................................................................................................................129 The Importance of Security Systems...............................................................................................................................129 Security System Preventive Maintenance.......................................................................................................................164 Disaster Planning.............................................................................................................................................................168 PART IV MATERIAL PLANNING...................................................................................................................................177 Chapter 15 How to Control Material Inventory.................................................................................................................177 Eight Basic Inventory Decisions.....................................................................................................................................177 Using the ABC Inventory Control Method.....................................................................................................................178 Cost Control....................................................................................................................................................................178 Three Methods Used to Calculate the Most Economic Order Quantity (EOQ)..............................................................180 How to Reduce Inventory................................................................................................................................................183 Chapter 16 How to Maintain an Effective Stores Control System....................................................................................185 Assigning Responsibility for Stores Control...................................................................................................................185 Establishing Procedures for Stores Control.....................................................................................................................186 Computerized Stores Control..........................................................................................................................................190 Implementation Plan for Bar-Coding Material................................................................................................................190 Radio Frequency Identification in Maintenance Stores...................................................................................................193 Chapter 17 How to Control the Use of Maintenance Tools and Equipment....................................................................197 The Role of the Tool Room Supervisor...........................................................................................................................197 Arranging Storage in the Tool Room..............................................................................................................................198 Four Control Procedures Used for Tool Issue and Return..............................................................................................200 How to Set Up an Effective Tool Control System..........................................................................................................202 Bar-Coding for Tool Control...........................................................................................................................................203 Seven Steps to Implementing Bar-Coding......................................................................................................................204 PART V EQUIPMENT RECORDS AND PREVENTIVE MAINTENANCE................................................................205 Chapter 18 How to Set Up and Maintain Equipment Records..........................................................................................205 How to Set Up an Equipment History System Using Equipment Identification and Specifications...............................205 How to Maintain an Equipment Repair History..............................................................................................................207 How to Use Equipment History to Optimize Repair.......................................................................................................207 Three Indicators That Can Improve Effectiveness in Repairs.........................................................................................208 How to Use Repair Statistics...........................................................................................................................................210 Staffing Prediction Models..............................................................................................................................................210 Chapter 19 How to Establish a Six Step Preventive Maintenance Program....................................................................211 Six Steps to Preventive Maintenance..............................................................................................................................211 How to Apply the Six Step PM Program to a Typical Installation..................................................................................216 Guidelines for Schedule Compliance Using Reports and Trend Charts..........................................................................218 Revising the Assignments and Schedule Calendar..........................................................................................................219 Staffing a PM Program....................................................................................................................................................219 Chapter 20 How to Implement a Predictive Maintenance System....................................................................................223 How Predictive Maintenance Compares to Other Types of Maintenance.......................................................................223 10 Advantages of Predictive Maintenance......................................................................................................................224 Eight Types of Predictive Maintenance and How They Work........................................................................................225 Infrared Thermography in Predictive Maintenance.........................................................................................................226 Maintenance Manager’s Standard Manual — Fifth Edition xi How Vibration Analysis Is Used in Predictive Maintenance...........................................................................................228 Common Causes for Excessive Vibration in Rotating Machines....................................................................................229 Problem-Solving Applications Using Vibration Analysis...............................................................................................233 Predictive Maintenance Using a Gas Analyzer................................................................................................................234 Using Leak Detection for Predictive Maintenance..........................................................................................................234 Using an Electric Generator for Predictive Maintenance.................................................................................................234 Using the Ammeter as a Predictive Maintenance Tool....................................................................................................234 Digital Multimeters..........................................................................................................................................................235 Fiber optic Cameras.........................................................................................................................................................235 Oil Analysis.....................................................................................................................................................................235 How to Select the Best PdM Technology for the Job......................................................................................................235 10 Steps to Setting Up Your Own Predictive Maintenance Program..............................................................................235 PART VI COMMON MAINTENANCE OPERATIONS AND TOOLS..........................................................................239 Chapter 21 Motion Economy: How to Work Smarter........................................................................................................239 Four Key Components of a Maintenance Job..................................................................................................................239 Job Preparation................................................................................................................................................................240 Key Management Benefit-Individual Ingenuity Versus Productivity..............................................................................241 How Common Maintenance Operations Indicate the Level of Effectiveness..................................................................241 How to Use Ladders and Scaffolds More Productively...................................................................................................241 How to Choose the Right Ladder.....................................................................................................................................242 Improved Material Handling With Manual and Electric Hoists......................................................................................243 Two Case Studies Involving Material Handling Equipment............................................................................................244 Chapter 22 How to Implement Motion Economy in Using Tools.......................................................................................245 14 Ways to Upgrade Tool Selection and Use..................................................................................................................249 Using Power Tools for Greater Productivity...................................................................................................................249 10 High-Productivity Ways to Get Tools and Workers to the Job...................................................................................250 Chapter 23 Cleaning, Inspecting and Lubricating Equipment..........................................................................................251 Cleaning...........................................................................................................................................................................251 Inspecting.........................................................................................................................................................................255 Lubricating.......................................................................................................................................................................257 Determining Type, Amount, and Frequency of Lubrication............................................................................................266 PART VII STRUCTURAL MAINTENANCE....................................................................................................................273 Chapter 24 Exterior Maintenance of Building Structures..................................................................................................273 Maintaining Building Foundations..................................................................................................................................273 Maintaining Building Walls.............................................................................................................................................277 How to Maintain Exterior Insulation and Finishing Systems (EIFS)...............................................................................280 Proper Maintenance of Windows and Doors...................................................................................................................284 Roof Maintenance............................................................................................................................................................285 Single-Ply Roofing Systems............................................................................................................................................288 Solutions to 36 Common Rooftop Problems...................................................................................................................289 Chapter 25 Interior Building Maintenance..........................................................................................................................297 Below-Grade Interior Building Maintenance...................................................................................................................297 Above-Grade Interior Building Maintenance..................................................................................................................297 Most Frequently Required Door Repairs.........................................................................................................................302 Care of Walls and Ceilings..............................................................................................................................................306 Five-Step Mold Correction..............................................................................................................................................308 Maintenance Manager’s Standard Manual — Fifth Edition xii PART VIII MECHANICAL MAINTENANCE.................................................................................................................311 Chapter 26 Mechanical Repair: Guidelines for Troubleshooting and Repair of Mechanical Problems.......................311 Typical Duties of a Machine Repair Worker...................................................................................................................311 Common Machine Components and How to Keep Them Working Smoothly...............................................................312 How to Maintain and Repair Pumps...............................................................................................................................317 Pump Life Cycle Costing................................................................................................................................................320 How to Calculate Pump Life Cycle Cost.........................................................................................................................323 Pipefitting: Proper Tools and Training Yield Major Saving Opportunities....................................................................324 New Plumbing Technology for a Better and Lower Life Cycle Cost..............................................................................328 Management Responsibility for an Effective Program...................................................................................................331 Machine Alignment Methods..........................................................................................................................................332 Hydraulic Power System Troubleshooting......................................................................................................................332 How to Optimize Precision Machine Tool Life Cycle....................................................................................................338 Chapter 27 Air Compressors................................................................................................................................................339 Repairing Compressors...................................................................................................................................................340 Air Compressor Inspection Checklist..............................................................................................................................341 Compressed Air Services................................................................................................................................................343 Compressed Air System Maintenance.............................................................................................................................344 Chapter 28 Air Conditioning................................................................................................................................................347 Air Conditioning Applications and Sizing......................................................................................................................347 How to Repair Wall and Window Units..........................................................................................................................347 Five Main Types of Central Air Conditioning Systems..................................................................................................348 A Typical Air Conditioning System Maintenance Program............................................................................................349 How to Realize Energy Cost Savings with Ice Storage...................................................................................................350 How to Improve Data Center Equipment Life Cycle with a Well Designed Cooling System........................................353 Chapter 29 Heating and Ventilation Systems......................................................................................................................355 How Heat Is Transferred.................................................................................................................................................355 Sizing Heating Systems...................................................................................................................................................356 Unit Heater Preventive Maintenance...............................................................................................................................356 Central Heater Preventive Maintenance..........................................................................................................................357 Radiator Maintenance for High-Efficiency Operation....................................................................................................358 Preventive Maintenance for Electric Resistance Heaters................................................................................................359 Types of Ventilating Systems..........................................................................................................................................359 How to Get the Best Operation from Your Fans.............................................................................................................362 How to Select the Right Fan for Your Application.........................................................................................................362 Costs................................................................................................................................................................................364 Equipment Specifications................................................................................................................................................364 How to Save Energy with Variable Speed Drives...........................................................................................................365 Fan Inspection Checklist.................................................................................................................................................365 PART IX ELECTRICAL/ELECTRONICS MAINTENANCE AND INSTRUMENT REPAIR..................................369 Chapter 30 Metrology and Instrumentation.......................................................................................................................369 What Is Metrology? ........................................................................................................................................................369 International Standards....................................................................................................................................................370 Gage Blocks....................................................................................................................................................................371 Instruments and Their Relative Precision........................................................................................................................371 How to Ensure Highly Accurate Measurement Application...........................................................................................372 Other Physical Variables and Instruments Used to Measure Them................................................................................373 Instrument Repair and Calibration Techniques...............................................................................................................375 Chapter 31 Electricians and Their Tools: How to Ensure High Productivity.................................................................381 Typical Electrician and Instrument Repair Job Classifications and Requirements.........................................................381 Electrical and Instrument Repair Tool Inventory: How to Be Sure You Have the Right Tools for the Job....................382 Maintenance Manager’s Standard Manual — Fifth Edition xiii Chapter 32 Lighting...............................................................................................................................................................387 Eight Benefits of Good Lighting in a Work Environment...............................................................................................387 How Proper Lighting Affects Work Productivity............................................................................................................388 Six Main Types of Lighting Fixtures and How They Work............................................................................................388 How to Determine Lighting Quality................................................................................................................................389 How to Design an Effective Lighting System in Three Steps..........................................................................................390 Group Relamping.............................................................................................................................................................392 Typical Relamping Duties...............................................................................................................................................397 Chapter 33 Motors and Generators......................................................................................................................................401 Motor Circuit Design.......................................................................................................................................................401 Generators........................................................................................................................................................................401 Motors..............................................................................................................................................................................404 Relationship Between Motor Controllers and Disconnect Devices.................................................................................408 How to Repair Electric Motors and Generators...............................................................................................................409 Troubleshooting Inspection and Testing Motors and Generators....................................................................................411 Five Tests to Use in Checking Motor Insulation.............................................................................................................411 How to Detect Electrically Caused Bearing Failure........................................................................................................412 Chapter 34 Emergency Power Systems................................................................................................................................413 Five Major Components of an Emergency Power System...............................................................................................413 Chapter 35 Distribution System Controls............................................................................................................................421 Building and Feeder Transformers..................................................................................................................................421 Power Distribution System Protection.............................................................................................................................424 Protective Device Preventive Maintenance Inspection and Testing................................................................................433 Chapter 36 Power Distribution System Planning and Sizing.............................................................................................435 Four Key Types of Loads and How to Size System Components for Them....................................................................435 How to Reduce Voltage Drop..........................................................................................................................................438 Seven Rules for Selecting Circuit Breakers.....................................................................................................................439 How to Plan Your Own Electrical Distribution System: A 14-Step Process...................................................................439 How to Determine the Capacitor Size Required to Optimize Power Factor....................................................................457 Nine Indications That It’s Time to Modernize Your Power Distribution System............................................................459 Chapter 37 Wiring Conduit and Junction Boxes.................................................................................................................461 Wiring..............................................................................................................................................................................461 Six Main Wiring Methods and the Advantages and Disadvantages of Each...................................................................462 A Typical Branch Circuit Wiring Conduit and Junction Box Installation.......................................................................464 Chapter 38 Batteries...............................................................................................................................................................467 Dry Cell Batteries............................................................................................................................................................467 Wet Cell or Storage Battery.............................................................................................................................................468 Wet Cell Battery..............................................................................................................................................................468 How to Care for Batteries................................................................................................................................................468 Four Factors to Consider When Selecting a Battery for Your Application......................................................................469 Other Design Considerations...........................................................................................................................................470 How to Maintain Battery Charging Equipment...............................................................................................................471 Chapter 39 High Voltage Power Supplies............................................................................................................................473 Lightning Arresters..........................................................................................................................................................474 High Voltage Maintenance Requirements.......................................................................................................................474 Types of Circuit Arrangements........................................................................................................................................475 PART X ROAD, FLEET, AND GROUND MAINTENANCE..........................................................................................477 Chapter 40 Road and Fleet Maintenance.............................................................................................................................477 Road Maintenance...........................................................................................................................................................477 A 10-Step Process for Road Repair Planning..................................................................................................................477 Planning Various Types of Road Maintenance................................................................................................................486 Machine Sweeping and Flushing.....................................................................................................................................490 Maintenance Manager’s Standard Manual — Fifth Edition xiv Intensive Policing: The “Hands-On” Approach to Road Cleanup...................................................................................490 Drainage Inlet Cleanout...................................................................................................................................................490 Dust Prevention...............................................................................................................................................................490 Ditching...........................................................................................................................................................................490 Flushing Culverts............................................................................................................................................................490 Leaf Pickup.....................................................................................................................................................................490 Mowing and Weed Cutting.............................................................................................................................................491 Snow and Ice Control......................................................................................................................................................491 Road Work Site Protection: Barricade Versus Channel..................................................................................................491 Fleet Maintenance...........................................................................................................................................................492 Setting Up a Fleet Maintenance Function.......................................................................................................................493 Management Control of Fleet Maintenance Work..........................................................................................................498 Fleet Equipment Replacement Planning and Control......................................................................................................498 Chapter 41 Grounds Maintenance.......................................................................................................................................503 Grounds Maintenance Planning and Organization: Two Key Planning Tools................................................................504 Guidelines for Providing Trouble-Free Lawn Care.........................................................................................................507 Five Steps to a Healthy Lawn..........................................................................................................................................507 Shrubs, Foundation and Border Plantings.......................................................................................................................509 Tree Care: How Pruning Can Promote Healthy Growth.................................................................................................510 Mining Gardeners’ Gold: How to Divide and Multiply Perennials.................................................................................511 Pest Control.....................................................................................................................................................................511 PART XI POWER PLANT MAINTENANCE...................................................................................................................515 Chapter 42 Energy Sources and Their Applications...........................................................................................................515 Energy Generation from Coal.........................................................................................................................................516 Fuel Oil............................................................................................................................................................................518 Natural Gas......................................................................................................................................................................518 Wood Waste and Bagasse...............................................................................................................................................518 Energy Sources and Total Cost of Operation..................................................................................................................519 Nuclear Energy................................................................................................................................................................519 Chapter 43 Boiler Maintenance............................................................................................................................................523 Typical Duties of a Boiler Operator................................................................................................................................523 Guidelines for Achieving Optimum Boiler Efficiency....................................................................................................523 Measuring Boiler Efficiency to Determine Maintenance Needs.....................................................................................524 Tips on Selecting the Right Boiler Equipment................................................................................................................528 Guidelines for Selecting Steam Generating Equipment..................................................................................................531 Main Boiler Failure Cause and Prevention......................................................................................................................532 Chapter 44 Turbine and Generator Maintenance..............................................................................................................535 How Cogeneration Can Provide Energy Savings for Your Plant....................................................................................535 Cogeneration: Partnership With Your Utility Company.................................................................................................535 How a Turbine-Generator Works....................................................................................................................................536 Seven Key Classifications of Steam Turbines.................................................................................................................536 Advantages of Steam Turbines Compared to Steam Engines.........................................................................................537 Tips on Maintaining Turbine Equipment........................................................................................................................537 Guidelines for Generator Maintenance............................................................................................................................539 Chapter 45 Power Plant Support Equipment......................................................................................................................541 Feedwater Pumps............................................................................................................................................................541 Air Heaters and Economizers..........................................................................................................................................542 Deaerators.......................................................................................................................................................................542 Superheaters....................................................................................................................................................................542 Condensers......................................................................................................................................................................542 Water Treatment..............................................................................................................................................................543 Piping Valves and Steam Traps.......................................................................................................................................543 Maintenance Manager’s Standard Manual — Fifth Edition xv

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MAINTENANCE MANAGER'S STANDARD MANUAL FIFTH EDITION THOMAS A. WESTERKAMP Editor-in-Chief William D. Mahoney, PE Technical Services Ana Varela Brett Crouse Cover Design Robert O. Wright BNi PUBLICATIONS, INC. 990 Park Center Drive Vista, CA 92081 1-888-264-2665 Copyright © 2013 by BNi Publications, Inc. All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. While diligent effort is made to provide reliable, accurate and up-to-date information, neither BNi Publications Inc., nor its authors or editors, can place a guarantee on the correctness of the data or information contained in this book. BNi Publications Inc., and its authors and editors, do hereby disclaim any responsibility or liability in connection with the use of this book or of any data or other information contained therein. ISBN 978-155-701-8106 ii Maintenance Manager’s Standard Manual — Fifth Edition Dedicated to Joyce Maintenance Manager’s Standard Manual — Fifth Edition iii TABLE OF CONTENTS Acknowledgments.................................................................................................................................................................iv What This Manual Will Do For You..................................................................................................................................v About the Author..................................................................................................................................................................viii Preface...................................................................................................................................................................................xix PART I MAINTENANCE MANAGEMENT.....................................................................................................................1 Chapter 1 Maintenance Management Strategy for Optimum Physical Plant Life Cycle................................................1 Leadership.......................................................................................................................................................................2 Six Critical Maintenance Management Principles..........................................................................................................2 How to Prepare a Written Maintenance Management Policy..........................................................................................3 Chapter 2 How to Organize and Staff the Maintenance Department...............................................................................13 How to Choose the Best Form for Your Department......................................................................................................13 How to Choose the Best Structure for Your Maintenance Organization by Using Job Evaluation................................16 How to Manage Contract Maintenance Work.................................................................................................................17 How to Optimize Staffing By Skill with Staffing Modeling...........................................................................................20 How to Prepare Your Own Organization Chart..............................................................................................................20 Chapter 3 Guidelines for Training Maintenance Personnel..............................................................................................23 Selecting Maintenance Personnel....................................................................................................................................23 Developing a Master Training Plan.................................................................................................................................25 Orienting New Employees..............................................................................................................................................26 Safety Training................................................................................................................................................................28 How to Train Managers to Be More Effective................................................................................................................28 Training Maintenance Planners.......................................................................................................................................30 Training Employees in Maintenance Trades...................................................................................................................30 How to Train Maintenance Trade Workers to Service Specific Equipment....................................................................32 Training Maintenance Apprentices.................................................................................................................................32 Multimedia Training.......................................................................................................................................................32 Computer-Based Training...............................................................................................................................................37 Chapter 4 How to Prepare a Workable Maintenance Budget...........................................................................................39 Types of Maintenance Budgets.......................................................................................................................................39 Two Effective Budget Preparation Methods...................................................................................................................40 Organizing for Budget Preparation.................................................................................................................................41 How to Prepare and Use Your Own Budget....................................................................................................................41 How to Bring Your Actual Costs in Line With the Budget.............................................................................................42 How to Use Cost Indexes to Project Future Costs...........................................................................................................44 Using Your CMMS to Track Actual Versus Budget.......................................................................................................45 Life Cycle Costing..........................................................................................................................................................46 Life Cycle Management..................................................................................................................................................46 Chapter 5 How to Set Up and Use Shop Floor Labor Controls.........................................................................................47 How to Obtain Information for Better Control of Maintenance Labor...........................................................................47 Developing a Weekly Maintenance Control Report........................................................................................................48 Preparing Trend Charts to Facilitate Maintenance Staffing............................................................................................48 Preparing a Staffing Model From Trends Data...............................................................................................................53 Chapter 6 How to Calculate Productivity Improvement Costs Versus Savings...............................................................55 How to Calculate Maintenance Labor Costs...................................................................................................................55 How to Use Cost Per Standard Hour to Calculate Savings.............................................................................................57 How to Determine the Base Cost Per Standard Hour......................................................................................................57 Comparing the Base Period to the Current Period to Calculate Savings.........................................................................59 How to Increase the Rate of Savings Generated.............................................................................................................59 Maintenance Manager’s Standard Manual — Fifth Edition ix PART II PLANNING AND SCHEDULING MAINTENANCE WORK..........................................................................63 Chapter 7 Planning Your Routine Repairs..........................................................................................................................63 Unplanned: Don’t Fix It If It Isn’t Broken.......................................................................................................................63 Planned: Don’t Wait Till It Breaks to Fix It....................................................................................................................63 Scoping the Job: How the Planned Maintenance Approach Works.................................................................................64 Typical Planner Job Descriptions....................................................................................................................................67 Job-Planning Audits Ensure Consistency and Accuracy.................................................................................................67 Chapter 8 How to Develop an Effective Work Order System............................................................................................69 How to Use the Work Order Form...................................................................................................................................69 A Six-Step Time Reporting Procedure to Complement the Work Order System............................................................76 When and How to Use a Weekly Work Order.................................................................................................................77 How to Successfully Control In-Process Work Orders....................................................................................................79 How to Use the Job Assignment Board...........................................................................................................................84 How to Use the Daily Maintenance Schedule..................................................................................................................86 Handling the Backlog of Maintenance Requests.............................................................................................................91 Responsibility for Backlog..............................................................................................................................................91 How to Measure and Classify Backlog............................................................................................................................91 Handling Unscheduled Work...........................................................................................................................................91 Handling Scheduled Work...............................................................................................................................................91 How to Use the Backlog to Calculate Workforce Requirements.....................................................................................92 How to Determine Weeks of Backlog for a Given Workforce Size................................................................................93 How to Use the Backlog File...........................................................................................................................................93 Work Order Location Control Using the Backlog File....................................................................................................94 How to Start a Backlog File.............................................................................................................................................94 Chapter 9 Planning for Emergency Maintenance Work....................................................................................................97 Guidelines for Effective Requests for Emergency Service..............................................................................................97 Responding to Emergencies.............................................................................................................................................97 How to Plan for Emergencies..........................................................................................................................................98 Effect of Emergencies on Staffing...................................................................................................................................99 Scheduling Versus Emergencies......................................................................................................................................100 Stocking Material for Emergencies..................................................................................................................................100 Handling Job Interruptions..............................................................................................................................................100 Operation Interruptions and Cost of Emergencies...........................................................................................................101 How to Get Emergencies Under Control.........................................................................................................................101 Using a Computerized Maintenance Management System to Control and Reduce Emergency Maintenance................101 Chapter 10 Planning and Controlling Major Equipment Reengineering and Overhaul Projects..................................103 Preliminary Planning.......................................................................................................................................................103 Three Essential Classes of Information for Preparing Engineering Specifications..........................................................104 12-Step Process for Preparing and Executing Major Overhauls......................................................................................106 Conducting a Prejob Conference to Determine the Scope of the Overhaul Project.........................................................108 Tracking and Controlling Reengineering Projects Using the Computer..........................................................................109 PART III FACILITY SPACE PLANNING, JUSTIFICATION AND CONSTRUCTION.............................................111 Chapter 11 Effective Space Planning for Your Facility......................................................................................................111 Three Main Types of Space Requirements......................................................................................................................111 How to Estimate Space Needs: Modular Space Planning................................................................................................112 Four Ways to Find More Space.......................................................................................................................................112 Chapter 12 How to Justify a New or Expanded Facility Plan............................................................................................115 Why Expand?...................................................................................................................................................................115 An Eight-Step Method to Improve Your Facility Space Use...........................................................................................115 Maintenance Manager’s Standard Manual — Fifth Edition x Chapter 13 Construction Project Planning and Scheduling..............................................................................................121 The Questioning Attitude................................................................................................................................................121 Estimating Project Costs.................................................................................................................................................121 How to Prepare Detailed Specifications..........................................................................................................................123 Seven Key Ingredients of a Successful Project Schedule................................................................................................123 Chapter 14 How to Maintain a Safe and Secure Workplace..............................................................................................127 Safety Considerations in Maintenance Work..................................................................................................................127 How to Evaluate Your Safety Program...........................................................................................................................129 Tips on Maintaining Equipment for Safety.....................................................................................................................129 The Importance of Security Systems...............................................................................................................................129 Security System Preventive Maintenance.......................................................................................................................164 Disaster Planning.............................................................................................................................................................168 PART IV MATERIAL PLANNING...................................................................................................................................177 Chapter 15 How to Control Material Inventory.................................................................................................................177 Eight Basic Inventory Decisions.....................................................................................................................................177 Using the ABC Inventory Control Method.....................................................................................................................178 Cost Control....................................................................................................................................................................178 Three Methods Used to Calculate the Most Economic Order Quantity (EOQ)..............................................................180 How to Reduce Inventory................................................................................................................................................183 Chapter 16 How to Maintain an Effective Stores Control System....................................................................................185 Assigning Responsibility for Stores Control...................................................................................................................185 Establishing Procedures for Stores Control.....................................................................................................................186 Computerized Stores Control..........................................................................................................................................190 Implementation Plan for Bar-Coding Material................................................................................................................190 Radio Frequency Identification in Maintenance Stores...................................................................................................193 Chapter 17 How to Control the Use of Maintenance Tools and Equipment....................................................................197 The Role of the Tool Room Supervisor...........................................................................................................................197 Arranging Storage in the Tool Room..............................................................................................................................198 Four Control Procedures Used for Tool Issue and Return..............................................................................................200 How to Set Up an Effective Tool Control System..........................................................................................................202 Bar-Coding for Tool Control...........................................................................................................................................203 Seven Steps to Implementing Bar-Coding......................................................................................................................204 PART V EQUIPMENT RECORDS AND PREVENTIVE MAINTENANCE................................................................205 Chapter 18 How to Set Up and Maintain Equipment Records..........................................................................................205 How to Set Up an Equipment History System Using Equipment Identification and Specifications...............................205 How to Maintain an Equipment Repair History..............................................................................................................207 How to Use Equipment History to Optimize Repair.......................................................................................................207 Three Indicators That Can Improve Effectiveness in Repairs.........................................................................................208 How to Use Repair Statistics...........................................................................................................................................210 Staffing Prediction Models..............................................................................................................................................210 Chapter 19 How to Establish a Six Step Preventive Maintenance Program....................................................................211 Six Steps to Preventive Maintenance..............................................................................................................................211 How to Apply the Six Step PM Program to a Typical Installation..................................................................................216 Guidelines for Schedule Compliance Using Reports and Trend Charts..........................................................................218 Revising the Assignments and Schedule Calendar..........................................................................................................219 Staffing a PM Program....................................................................................................................................................219 Chapter 20 How to Implement a Predictive Maintenance System....................................................................................223 How Predictive Maintenance Compares to Other Types of Maintenance.......................................................................223 10 Advantages of Predictive Maintenance......................................................................................................................224 Eight Types of Predictive Maintenance and How They Work........................................................................................225 Infrared Thermography in Predictive Maintenance.........................................................................................................226 Maintenance Manager’s Standard Manual — Fifth Edition xi How Vibration Analysis Is Used in Predictive Maintenance...........................................................................................228 Common Causes for Excessive Vibration in Rotating Machines....................................................................................229 Problem-Solving Applications Using Vibration Analysis...............................................................................................233 Predictive Maintenance Using a Gas Analyzer................................................................................................................234 Using Leak Detection for Predictive Maintenance..........................................................................................................234 Using an Electric Generator for Predictive Maintenance.................................................................................................234 Using the Ammeter as a Predictive Maintenance Tool....................................................................................................234 Digital Multimeters..........................................................................................................................................................235 Fiber optic Cameras.........................................................................................................................................................235 Oil Analysis.....................................................................................................................................................................235 How to Select the Best PdM Technology for the Job......................................................................................................235 10 Steps to Setting Up Your Own Predictive Maintenance Program..............................................................................235 PART VI COMMON MAINTENANCE OPERATIONS AND TOOLS..........................................................................239 Chapter 21 Motion Economy: How to Work Smarter........................................................................................................239 Four Key Components of a Maintenance Job..................................................................................................................239 Job Preparation................................................................................................................................................................240 Key Management Benefit-Individual Ingenuity Versus Productivity..............................................................................241 How Common Maintenance Operations Indicate the Level of Effectiveness..................................................................241 How to Use Ladders and Scaffolds More Productively...................................................................................................241 How to Choose the Right Ladder.....................................................................................................................................242 Improved Material Handling With Manual and Electric Hoists......................................................................................243 Two Case Studies Involving Material Handling Equipment............................................................................................244 Chapter 22 How to Implement Motion Economy in Using Tools.......................................................................................245 14 Ways to Upgrade Tool Selection and Use..................................................................................................................249 Using Power Tools for Greater Productivity...................................................................................................................249 10 High-Productivity Ways to Get Tools and Workers to the Job...................................................................................250 Chapter 23 Cleaning, Inspecting and Lubricating Equipment..........................................................................................251 Cleaning...........................................................................................................................................................................251 Inspecting.........................................................................................................................................................................255 Lubricating.......................................................................................................................................................................257 Determining Type, Amount, and Frequency of Lubrication............................................................................................266 PART VII STRUCTURAL MAINTENANCE....................................................................................................................273 Chapter 24 Exterior Maintenance of Building Structures..................................................................................................273 Maintaining Building Foundations..................................................................................................................................273 Maintaining Building Walls.............................................................................................................................................277 How to Maintain Exterior Insulation and Finishing Systems (EIFS)...............................................................................280 Proper Maintenance of Windows and Doors...................................................................................................................284 Roof Maintenance............................................................................................................................................................285 Single-Ply Roofing Systems............................................................................................................................................288 Solutions to 36 Common Rooftop Problems...................................................................................................................289 Chapter 25 Interior Building Maintenance..........................................................................................................................297 Below-Grade Interior Building Maintenance...................................................................................................................297 Above-Grade Interior Building Maintenance..................................................................................................................297 Most Frequently Required Door Repairs.........................................................................................................................302 Care of Walls and Ceilings..............................................................................................................................................306 Five-Step Mold Correction..............................................................................................................................................308 Maintenance Manager’s Standard Manual — Fifth Edition xii PART VIII MECHANICAL MAINTENANCE.................................................................................................................311 Chapter 26 Mechanical Repair: Guidelines for Troubleshooting and Repair of Mechanical Problems.......................311 Typical Duties of a Machine Repair Worker...................................................................................................................311 Common Machine Components and How to Keep Them Working Smoothly...............................................................312 How to Maintain and Repair Pumps...............................................................................................................................317 Pump Life Cycle Costing................................................................................................................................................320 How to Calculate Pump Life Cycle Cost.........................................................................................................................323 Pipefitting: Proper Tools and Training Yield Major Saving Opportunities....................................................................324 New Plumbing Technology for a Better and Lower Life Cycle Cost..............................................................................328 Management Responsibility for an Effective Program...................................................................................................331 Machine Alignment Methods..........................................................................................................................................332 Hydraulic Power System Troubleshooting......................................................................................................................332 How to Optimize Precision Machine Tool Life Cycle....................................................................................................338 Chapter 27 Air Compressors................................................................................................................................................339 Repairing Compressors...................................................................................................................................................340 Air Compressor Inspection Checklist..............................................................................................................................341 Compressed Air Services................................................................................................................................................343 Compressed Air System Maintenance.............................................................................................................................344 Chapter 28 Air Conditioning................................................................................................................................................347 Air Conditioning Applications and Sizing......................................................................................................................347 How to Repair Wall and Window Units..........................................................................................................................347 Five Main Types of Central Air Conditioning Systems..................................................................................................348 A Typical Air Conditioning System Maintenance Program............................................................................................349 How to Realize Energy Cost Savings with Ice Storage...................................................................................................350 How to Improve Data Center Equipment Life Cycle with a Well Designed Cooling System........................................353 Chapter 29 Heating and Ventilation Systems......................................................................................................................355 How Heat Is Transferred.................................................................................................................................................355 Sizing Heating Systems...................................................................................................................................................356 Unit Heater Preventive Maintenance...............................................................................................................................356 Central Heater Preventive Maintenance..........................................................................................................................357 Radiator Maintenance for High-Efficiency Operation....................................................................................................358 Preventive Maintenance for Electric Resistance Heaters................................................................................................359 Types of Ventilating Systems..........................................................................................................................................359 How to Get the Best Operation from Your Fans.............................................................................................................362 How to Select the Right Fan for Your Application.........................................................................................................362 Costs................................................................................................................................................................................364 Equipment Specifications................................................................................................................................................364 How to Save Energy with Variable Speed Drives...........................................................................................................365 Fan Inspection Checklist.................................................................................................................................................365 PART IX ELECTRICAL/ELECTRONICS MAINTENANCE AND INSTRUMENT REPAIR..................................369 Chapter 30 Metrology and Instrumentation.......................................................................................................................369 What Is Metrology? ........................................................................................................................................................369 International Standards....................................................................................................................................................370 Gage Blocks....................................................................................................................................................................371 Instruments and Their Relative Precision........................................................................................................................371 How to Ensure Highly Accurate Measurement Application...........................................................................................372 Other Physical Variables and Instruments Used to Measure Them................................................................................373 Instrument Repair and Calibration Techniques...............................................................................................................375 Chapter 31 Electricians and Their Tools: How to Ensure High Productivity.................................................................381 Typical Electrician and Instrument Repair Job Classifications and Requirements.........................................................381 Electrical and Instrument Repair Tool Inventory: How to Be Sure You Have the Right Tools for the Job....................382 Maintenance Manager’s Standard Manual — Fifth Edition xiii Chapter 32 Lighting...............................................................................................................................................................387 Eight Benefits of Good Lighting in a Work Environment...............................................................................................387 How Proper Lighting Affects Work Productivity............................................................................................................388 Six Main Types of Lighting Fixtures and How They Work............................................................................................388 How to Determine Lighting Quality................................................................................................................................389 How to Design an Effective Lighting System in Three Steps..........................................................................................390 Group Relamping.............................................................................................................................................................392 Typical Relamping Duties...............................................................................................................................................397 Chapter 33 Motors and Generators......................................................................................................................................401 Motor Circuit Design.......................................................................................................................................................401 Generators........................................................................................................................................................................401 Motors..............................................................................................................................................................................404 Relationship Between Motor Controllers and Disconnect Devices.................................................................................408 How to Repair Electric Motors and Generators...............................................................................................................409 Troubleshooting Inspection and Testing Motors and Generators....................................................................................411 Five Tests to Use in Checking Motor Insulation.............................................................................................................411 How to Detect Electrically Caused Bearing Failure........................................................................................................412 Chapter 34 Emergency Power Systems................................................................................................................................413 Five Major Components of an Emergency Power System...............................................................................................413 Chapter 35 Distribution System Controls............................................................................................................................421 Building and Feeder Transformers..................................................................................................................................421 Power Distribution System Protection.............................................................................................................................424 Protective Device Preventive Maintenance Inspection and Testing................................................................................433 Chapter 36 Power Distribution System Planning and Sizing.............................................................................................435 Four Key Types of Loads and How to Size System Components for Them....................................................................435 How to Reduce Voltage Drop..........................................................................................................................................438 Seven Rules for Selecting Circuit Breakers.....................................................................................................................439 How to Plan Your Own Electrical Distribution System: A 14-Step Process...................................................................439 How to Determine the Capacitor Size Required to Optimize Power Factor....................................................................457 Nine Indications That It’s Time to Modernize Your Power Distribution System............................................................459 Chapter 37 Wiring Conduit and Junction Boxes.................................................................................................................461 Wiring..............................................................................................................................................................................461 Six Main Wiring Methods and the Advantages and Disadvantages of Each...................................................................462 A Typical Branch Circuit Wiring Conduit and Junction Box Installation.......................................................................464 Chapter 38 Batteries...............................................................................................................................................................467 Dry Cell Batteries............................................................................................................................................................467 Wet Cell or Storage Battery.............................................................................................................................................468 Wet Cell Battery..............................................................................................................................................................468 How to Care for Batteries................................................................................................................................................468 Four Factors to Consider When Selecting a Battery for Your Application......................................................................469 Other Design Considerations...........................................................................................................................................470 How to Maintain Battery Charging Equipment...............................................................................................................471 Chapter 39 High Voltage Power Supplies............................................................................................................................473 Lightning Arresters..........................................................................................................................................................474 High Voltage Maintenance Requirements.......................................................................................................................474 Types of Circuit Arrangements........................................................................................................................................475 PART X ROAD, FLEET, AND GROUND MAINTENANCE..........................................................................................477 Chapter 40 Road and Fleet Maintenance.............................................................................................................................477 Road Maintenance...........................................................................................................................................................477 A 10-Step Process for Road Repair Planning..................................................................................................................477 Planning Various Types of Road Maintenance................................................................................................................486 Machine Sweeping and Flushing.....................................................................................................................................490 Maintenance Manager’s Standard Manual — Fifth Edition xiv Intensive Policing: The “Hands-On” Approach to Road Cleanup...................................................................................490 Drainage Inlet Cleanout...................................................................................................................................................490 Dust Prevention...............................................................................................................................................................490 Ditching...........................................................................................................................................................................490 Flushing Culverts............................................................................................................................................................490 Leaf Pickup.....................................................................................................................................................................490 Mowing and Weed Cutting.............................................................................................................................................491 Snow and Ice Control......................................................................................................................................................491 Road Work Site Protection: Barricade Versus Channel..................................................................................................491 Fleet Maintenance...........................................................................................................................................................492 Setting Up a Fleet Maintenance Function.......................................................................................................................493 Management Control of Fleet Maintenance Work..........................................................................................................498 Fleet Equipment Replacement Planning and Control......................................................................................................498 Chapter 41 Grounds Maintenance.......................................................................................................................................503 Grounds Maintenance Planning and Organization: Two Key Planning Tools................................................................504 Guidelines for Providing Trouble-Free Lawn Care.........................................................................................................507 Five Steps to a Healthy Lawn..........................................................................................................................................507 Shrubs, Foundation and Border Plantings.......................................................................................................................509 Tree Care: How Pruning Can Promote Healthy Growth.................................................................................................510 Mining Gardeners’ Gold: How to Divide and Multiply Perennials.................................................................................511 Pest Control.....................................................................................................................................................................511 PART XI POWER PLANT MAINTENANCE...................................................................................................................515 Chapter 42 Energy Sources and Their Applications...........................................................................................................515 Energy Generation from Coal.........................................................................................................................................516 Fuel Oil............................................................................................................................................................................518 Natural Gas......................................................................................................................................................................518 Wood Waste and Bagasse...............................................................................................................................................518 Energy Sources and Total Cost of Operation..................................................................................................................519 Nuclear Energy................................................................................................................................................................519 Chapter 43 Boiler Maintenance............................................................................................................................................523 Typical Duties of a Boiler Operator................................................................................................................................523 Guidelines for Achieving Optimum Boiler Efficiency....................................................................................................523 Measuring Boiler Efficiency to Determine Maintenance Needs.....................................................................................524 Tips on Selecting the Right Boiler Equipment................................................................................................................528 Guidelines for Selecting Steam Generating Equipment..................................................................................................531 Main Boiler Failure Cause and Prevention......................................................................................................................532 Chapter 44 Turbine and Generator Maintenance..............................................................................................................535 How Cogeneration Can Provide Energy Savings for Your Plant....................................................................................535 Cogeneration: Partnership With Your Utility Company.................................................................................................535 How a Turbine-Generator Works....................................................................................................................................536 Seven Key Classifications of Steam Turbines.................................................................................................................536 Advantages of Steam Turbines Compared to Steam Engines.........................................................................................537 Tips on Maintaining Turbine Equipment........................................................................................................................537 Guidelines for Generator Maintenance............................................................................................................................539 Chapter 45 Power Plant Support Equipment......................................................................................................................541 Feedwater Pumps............................................................................................................................................................541 Air Heaters and Economizers..........................................................................................................................................542 Deaerators.......................................................................................................................................................................542 Superheaters....................................................................................................................................................................542 Condensers......................................................................................................................................................................542 Water Treatment..............................................................................................................................................................543 Piping Valves and Steam Traps.......................................................................................................................................543 Maintenance Manager’s Standard Manual — Fifth Edition xv

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