Pre-Solicitation Conference: Facilities Maintenance Services June 17-18, 2002 1 RFP2-36501...

Pre-Solicitation Conference: Facilities Maintenance ServicesJune 17-18, 2002

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PREDICTIVE MAINTENANCE (PdM)

Plant Engineering Branch Code JFP

NASA Ames Research Center

Mike DiSanto


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PREDICTIVE MAINTENANCE OUTLINE

• Predictive Testing and Inspection (PT&I)

• Acceptance of New/Rebuilt Equipment

• Failure Modes and Effects Analysis (FMEA)


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PREDICTIVE MAINTENANCE (PdM) - 1

• Predictive Maintenance (PdM) based on Predictive Testing and Inspection (PT&I) technologies available and Failure Modes and Effects Analysis (FMEA)

• Develop a PdM program under the firm fixed-price contract and implement on-site– Take into consideration risk of production loss if equipment

fails– Possible cost savings– Regulatory requirements

– Primary Goals• In- line with best industry practices• Economically beneficial


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• Predictive Testing and Inspection (PT&I)– Contractor is responsible for performing PT&I as part of its

recurring services under the firm fixed price portion of the contract (para. C5.3.B.2)

– Contractor shall have experience in vibration analysis and thermography at a minimum of Level I certification (para. C1.2.P.7)

– PT&I Technologies are outlined in Attachment J-C1.6– The Contractor may substitute PT&I for time based PM– The Contractor may use PT&I results to document proposed

changes that reduce (or increase) the current work load


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• Acceptance of New and Re-built Equipment– Shall participate in the acceptance process of newly installed

equipment of value• Verified to standards set forth in APD 8830.1, Facility/Equipment

Inspection and Acceptance Program Using Reliability-Centered Maintenance (RCM) Technologies

• Improve initial equipment condition• Eliminate Installation defects

• Failure Modes and Effects Analysis (FMEA)– Shall perform as part of the on-going RCM/PdM program– Shall contain the following information

• Address functional failure• Dominant failure modes• Failure cause and effect• Recommended actions


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RCM/PdM OVERVIEW

• The purpose of this brief is to provide you with an overview of the current RCM/PdM program at Ames


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IN-HOUSE PT&I TECHNOLOGIES IN USE

• Technology– Periodic Vibration Analysis– Oil & Wear Particle

Analysis– Thermography– Motor stator analysis &

electrical surge testing– Motor Current Signature

Analysis– Airborne Ultrasonics

• Application– All Rotating Equipment– Critical & Low Speed

Equipment– Electrical Components,

Heat Insulation, mech. Components

– Motor stator and insulation breakdown

– Motor rotor bars, eccentricity

– Steam trap, compressed gases, vacuum leaks


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CURRENT EQUIPMENT MONITORED

• Examples of Current Equipment Types Being Monitored

– Boilers and Boiler Fans– Chillers and Chilled Water Pumps– Mixing Pumps– Air Handlers– Critical Electric Motors– Sewage Pumps– Electrical Substation Equipment


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DATA COLLECTION

• Work orders are generated by MAXIMO®

• Route is downloaded to machinery analyzer• Data is collected and downloaded into RBMWare®

software• After analysis, completed work order is returned to

MAXIMO®


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PT&I TO DATE

• Total Buildings Analyzed 135• Buildings Chosen for PT&I 45• PT&I Installation Complete 45• Active Routes and Data Collection 45


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OVERSIGHT

• Oversight for the RCM Program is provided by the Plant Engineering Branch RCM Program Office

• The Plant Engineering Branch will use PT&I technologies to review work performance and PT&I and FMEA data collected by contractor personnel


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Facility Management Control System

(FMCS)



Steve Frankel


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INTRODUCTION TO FMCS

• What is the NASA Ames FMCS

• How is the Ames FMCS used today

• How is monitoring and control achieved

• What is controlled and monitored

• What is next


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WHAT IS THE NASA AMES FMCS

• A computer-based Building Automation System

• Monitors and controls various mechanical and

electrical systems

• Monitors critical labs, rooms, and spaces

• Allows remote monitoring and control

• Alerts maintenance staff when abnormal conditions

occur


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HOW IS THE AMES FMCS USED TODAY

• Monitoring and control 24/7

– HVAC, Mechanical systems, specific laboratory related

systems

• Pre-emptive action to avoid customer trouble calls

• Maintenance tool

• Data collection, trending, and fault diagnosis

• Energy conservation


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HOW IS MONITORING AND CONTROL ACHIEVED

• One host computer on-site– PC running Windows 2000NT operating system– Siemens Apogee Insight Building Automation System

• Four (4) operator consoles on-site– PC’s running Windows 2000NT operating system

• Four (4) high speed network communication trunks• 101 major buildings serviced by the FMCS

– 174 field panels– 3,876 physical I/O points (hardware)– 3,405 virtual points (software)– Programmed to generate over 2,450 alarms


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WHAT IS CONTROLLED AND MONITORED

• Air Conditioning Equipment• Air Handlers• Boilers• Chillers• Control Valves• Cooling Towers• Power Meters• Gas Meters

• Generators• Humidities• UPS• Fans• Pumps• Sump Levels• Temperatures• Environmental Chambers


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WHAT IS NEXT FOR THE FMCS

• Possible expansion– New facilities located on Ames Research Center– New facilities located on Moffett Airfield Complex– New facilities that are part of the NASA Research Park (NRP)

• Improvements to existing system– Remote connections– Wireless data communications– Speed– Upgrades to hardware and software


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Computerized Maintenance Management System

(CMMS)




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INTRODUCTION TO CMMS

• What is the NASA Ames CMMS

• How is the Ames CMMS used today

• What is tracked with the CMMS

• Who uses the CMMS

• What is next for the CMMS


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WHAT IS THE NASA AMES CMMS

• A commercial “off-the-shelf” product (COTS)

– Maximo by PSDI, Inc.

• Used to manage the performance of maintenance work

• Used to manage maintenance work data

– TC, PM, PdM, and condition of equipment

– Labor

• Used to manage plant equipment data

– Equipment inventory

– Parts inventory


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HOW IS THE AMES CMMS USED TODAY

• Generation of Work Order Tasks– Preventive Maintenance work orders– Predictive Maintenance work orders (PT&I)– Trouble Call work orders– Condition Assessments

• Data Collection

• Report Creation and Generation


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WHAT IS NEXT FOR THE CMMS

• Possible Expansion/Changes– Addition of equipment from other agencies/companies– Migration to web-based server technology (IFMP)

• Improvements to Existing System– Expansion of paperless input/output work flow– Wireless data communications– Upgrades to hardware and software– Expansion of bar coding equipment and procedures– Process work flow improvements


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MicroRoofer




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INTRODUCTION TO MICROROOFER

• What is the NASA Ames MicroRoofer System

• History of MicroRoofer

• Purpose

• Objectives

• Benefits of MicroRoofer

• Reports

• Examples of Worksheets and ACAD Files


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WHAT IS THE AMES MICROROOFER SYSTEM

• An Engineering Management System

– PC based computerized system

– Database, analysis, and cost estimating features

– AutoCAD graphics of roofs

• Types of Roofs

– Bituminous built-up roofs

– Single ply roofs

– Shingled roofs


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OBJECTIVES OF MICROROOFER

• Systematic– Inclusive of wide ranging variables and conditions found on

typical facilities

• Objective– Remove as much individual subjectivity from evaluations as

possible

• Repeatable– Periodic inspections must be consistent for data input and

report output

• Efficient– Checklist forms and computer-based data management– Training on MicroRoofer Inspection Protocols


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BENEFITS OF MICROROOFER

• A complete inventory of the roof area, including roof system components, features, and penetrations

• Update of roof area plans on electronic media in AutoCAD

• Detection of defects by:– Wet insulation sampling and analysis– Visual inspection of membrane and flashings

• Summarizes findings in a ten year maintenance/repair program

• Determination of remaining useful life


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HISTORY OF MICROROOFER

• Developed by the U.S. Army Construction Engineering Research Laboratory

• Technical Assistance Provided by:– U.S. Army Cold Regions Research and Engineering Labs– U.S. Army Engineering and Housing Support Center– U.S. Navy– University of Illinois Technical Assistance Center– Civilian Roofing Consultants


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Integrated Pest Management (IPM)

and

Environmental Support Services



Kelly Kasser


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WHO AM I

• KELLY KASSER

– Assistant Branch Chief, Code JFP

– Background in Hazardous Materials Response and Safety

Management

– BS Degree in Management

– MPH Pending


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OVERVIEW

• Integrated Pest Management (IPM)

– Integrated Vegetation Management (IVM)

• Settling Basin

• Plumbing and Piping of Processed Water

• Remediation and Composting


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HOW IS THE AMES FMCS USED TODAY


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IPM

• Is a science-based pest management approach which uses information about the biology and habitat requirements of the pest to design an environmentally sound, proactive management program

• To the degree possible, pests and the conditions conducive to their presence, are permanently reduced or removed using non-chemical methods


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GENERAL OBJECTIVE OF IPM

• To replace reactive pesticide applications with an effective and affordable Integrated Pest Management (IPM) monitoring system and management program that focuses on long-term pest prevention and reducing the use of toxic materials


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SPECIFIC IPM GOALS FOR NASA AMES

• Reduce Pesticide use at Moffett Field

• Use least-toxic chemical control methods

• Customize program to the pest and the site

• Expand program to the entire site

• Include grounds maintenance activities


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THE BUILDINGS - 1

• A total of 300,000 square feet of space

• Single story and multiple story buildings

• Office space and general use areas

• A pest monitoring system was established to identify

where chronic pest problems were located and the

conditions that were attracting pests

• Trouble Calls


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THE BUILDINGS - 2

• To rid the building of existing pests, a combination of

trapping, insect pheromones that disrupt maturation,

and small amounts of low-toxic insecticidal baits solved

most insect and rodent problems. The on-going

monitoring program was used to fine-tune and evaluate

the program to maximize its impact


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THE BUILDINGS - 3

• Within two years ( 1996-1998) the structural IPM program reduced pesticide use from 4000 gallons per year down to 13.2 gallons per year and substantially improved the overall quality of pest control


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INTEGRATED VEGETATION MANAGEMENT

• When applied to weeds, IPM concepts and methods

are referred to as “Integrated Vegetation Management

(IVM).”

• Beginning in 1997, and accelerating in 1998, pilot IVM

programs were established to address weed problems

in landscaped areas, as well as on roadsides, and

canals


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IVM - THE PROBLEMS

• Bare or undisturbed soil is the ideal habitat for weed growth, which nature uses to cover and protect soil from erosion and other damage. Thus, in the long-term, the more weeds are sprayed or mowed, the more difficult weed control becomes over time as weed species resistant to herbicides or tolerant of mowing eventually move in and take over


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IVM - THE METHODS

• IVM methods reduce or remove habitat conditions that favor weeds, and replace them with beneficial, non-weedy plants or barriers such as mulches, weed barrier fabrics or weed eaters suited to both the uses of the site and the available maintenance resources


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PUMPING AND PIPING FOR PROCESSED WATER


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SETTLING BASIN


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REMEDIATION AND COMPOSTING - 1


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Pre-Solicitation Conference: Facilities Maintenance Services June 17-18, 2002 1 RFP2-36501...

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