An essential on-the-job resource, Facility Manager's Maintenance Handbook presents step-by-step coverage of the planning, design, and execution of operations and maintenance procedures for structures, equipment, and systems in any type of facility. This career-building reference provides the tools needed to streamline facility management processes…reduce operational costs…and ensure the effective utilization, maintenance, repair, and renovation of existing physical assets.
Now with 40% new information, this Second Edition includes brand-new chapters on emergency response procedures…maintenance operations benchmarking…capital and operational budgets management…boiler and steam plant operations... and other vital topics. The only book of its kind to cover both operations and maintenance, the updated Facility Manager's Maintenance Handbook features:
Updated information on mechanical equipment and systems maintenance
The latest fire protection procedures
A comprehensive account of building codes
Guidance on hazardous materials handling
Excellent preparation for the IFMA Certified Facility Manager (CFM) qualification
Review
Excerpt
While vibration monitoring is certainly the most widely used tool for determining rotating machinery condition, oil analysis will, in many situations, provide an earlier indication that abnormal or premature wear is in progress. Oil monitoring and analysis is especially appropriate for slow-speed machines, reciprocating machines and gearboxes, as they usually show developing faults earlier using oil versus vibration analysis.
As internal machine components wear, they leave the wear particles in the lubricating oil. Identifying the existence, size, shape and elements of the wear particles leads to identifying the particular component experiencing the wear. This valuable information can then be used to aid in determining the ability of the machine to continue operating, planning for repairs, ordering necessary parts, and preventing unnecessary, unplanned downtime.
Table of Contents
Part 1 Organizing for Maintenance Operations
Chapter 1. Program Organizational Structure
Richard S. Nietubicz and Bernard T. Lewis
1.1 Responsibilities and Authority
1.2 The Facility Manager
1.3 Facility Planning
1.4 Facility Engineering and Design
1.5 Engineering Support to the
Maintenance and Operations Functions
1.5.1 Specialized technical services
1.5.2 Cost reduction
1.6 Construction of Facilities and
Installation of Equipment and Systems
1.6.1 Personnel in facility
organizations-Single-project
worker-hour limit
1.6.2 Contract work inspections
1.6.3 Construction meetings
1.6.4 Contract administration
1.7 Maintenance of Plant Facilities and
Equipment
1.7.1 Operations and maintenance
workload
1.7.2 Evaluation of performance
1.8 Preventive Maintenance
1.9 Routine Maintenance
1.10 Major Repairs
1.11 Alterations and Improvements
1.12 Housekeeping
1.13 Principles of Organization
1.13.1 Definition and scope
1.14 Facilities Management Defined
1.14.1 Facility management functions
1.14.2 Organizational prerequisites
1.15 Analyzing the Needs
1.16 Establishing Goals and Objectives
1.17 Administering the Organization
1.18 Organization vs. People
1.19 Performance Measurement
1.20 Organizing Considerations for
Outsourcing Functions
References
Chapter 2. Program Operations
Michael D. Burns
2.1 Designing the Maintenance Management
Information System
2.1.1 What kind of information do you
need?
2.1.2 Common information needs
2.1.3 Special information needs
2.1.4 Hardware and software requirements
2.2 Functions of the System
2.2.1 Maintenance planning and
scheduling
2.2.2 Corrective maintenance
2.2.3 "House calls"
2.2.4 Projects
2.2.5 Parts availability
2.2.6 Information system integration
2.2.7 Use of preventive and predictive
information
2.2.8 Warranties information
2.2.9 Production and financial report
2.2.10 Personnel data
2.2.11 Quality control and quality
assurance information
2.3 Annual Maintenance Operational Report
2.3.1 Elements of a successful system
2.3.2 Maintenance history vs. machinery
history
2.3.3 Quality management impact
2.3.4 Maintenance "outplanning"
2.4 Maintenance Management Manual
2.4.1 Scope of the manual
2.4.2 Maintenance objective
2.4.3 Lines of authority
2.4.4 Task responsibility
2.4.5 Corrective action
2.4.6 Regular review of feedback
2.4.7 Document control
2.4.8 Regular review of entire system
2.5 Other Considerations
Part 2 Facility Operations and Maintenance Plans
Chapter 3. Operations Plans
Richard P. Payant
3.1 Management Operational Plan
3.1.1 Work control methods and
procedures
3.1.2 Work control center
3.1.3 Service orders (SO)
3.1.4 Work orders (WO)
3.1.5 Standing operating orders (SOO)
3.1.6 Preventive maintenance (PM)
3.1.7 Work Priority System
3.1.8 Emergency priority
3.1.9 Urgent priority
3.1.10 Routine priority
3.1.11 Work approval
3.1.12 Planning
3.1.13 Scheduling
3.1.14 Execution of work
3.1.15 Checked and inspected
3.1.16 Closed and cost accounted
3.1.17 Results recorded, analyzed, and
measured
3.1.18 Feedback
3.2 Building Operational Plan
3.2.1 Scheduling work
3.2.2 Shutdowns and startups
3.2.3 Emergency situations
3.2.4 Trouble diagnosis and coordination
3.2.5 Coordination with third parties
3.2.6 Benchmarking
3.2.7 Statistical process control
3.3 Comprehensive Facility Operational
Plans
3.3.1 Emergency response plan
3.3.2 Hazardous materials plan
3.3.3 Refrigerant management
3.3.4 Safety plans
3.3.5 Fire protection plans
3.3.6 Labor unrest
3.4 Facility Occupant Support Plan
3.4.1 Improving perceptions
3.4.2 Determining wants
3.4.3 Provide feedback
3.5 Quality Control Plan
3.5.1 Specific QCP objectives
3.5.2 Inspection system
3.5.3 Inspections by FD personnel
3.5.4 Identifying and tracking
substandard performance
3.5.5 Correcting deficiencies
3.6 Summary
References
Chapter 4. Maintenance Plans
William G. Suter, Jr.
4.1 Equipment, Systems, and Structure
Building Tours
4.1.1 Introduction
4.1.2 Purpose
4.1.3 Implementation
4.1.4 Scheduling
4.1.5 Equipment and system logs
4.1.6 Technology
4.1.7 Staffing
4.1.8 Documentation
4.1.9 Summary
4.2 Engineered Performance Standards
(EPS) Usage Plan
4.2.1 Basis for all types of labor
time standards (EPS)
4.2.2 Computerization
4.2.3 Why have labor time standards
(EPS)?
4.2.4 Types of EPS
4.2.5 Estimate
4.2.6 Historical work standards
4.2.7 Direct observed standards
4.2.8 Published engineered performance
standards
4.2.9 Engineered performance standards
(EPS)
4.2.10 Management manuals
4.2.11 Trades manuals
4.2.12 General Services Administration:
Public buildings maintenance guides and
time standards
4.2.13 R.S. Means maintenance standards
4.2.14 How to use standards, a
step-by-step guide
References
Chapter 5. Preventive Maintenance (PM) Plan
J.R. Ruta and Tony Graff
5.1 PM Procedures
5.1.1 Dollars and cents
5.2 Automated Program-Software
5.2.1 Getting started with a CMMS
5.2.2 Flexibility and user friendliness
5.2.3 Generic CMMS function
5.2.4 Implementing a CMMS
5.3 Maintenance File Cards
5.4 Equipment History Files
5.5 Verifying Facility Inventory
5.5.1 Computerizing inventory
5.5.2 Inventory control (tracking)
5.6 Labeling Facility Equipment
5.7 Annual PM Schedule
5.8 Setting Special Schedules
5.9 Opening or Dismantling Equipment
5.10 Computerized Records and Reporting
Chapter 6. Predictive Maintenance Plan
Joseph E. Humphrey
6.1 Benefits of Predictive Maintenance
6.2 Predictive Maintenance Technologies
6.2.1 Vibration monitoring
6.2.2 Infrared (IR) thermography
6.2.3 Oil analysis
6.2.4 Ultrasound
6.2.5 Integration
6.2.6 Expert systems
6.3 Predictive Process
6.3.1 Program startup
6.3.2 Measure program effectiveness
6.3.3 Review and revise program
References
Chapter 7. Indoor Air Quality (IAQ) Plan
Richard M. Silberman
7.1 IAQ and the Contemporary Facility
Manager
7.1.1 Indoor pollutants
7.1.2 Sick building syndrome
7.1.3 Causes and considerations
7.1.4 Facility managers go proactive
7.2 The Proactive Facility Inspection and
Sampling Techniques
7.2.1 Objectives
7.2.2 Scope of proactive facility
inspection
7.2.3 Analysis of building data
7.2.4 HVAC inspection
7.2.5 Air quality tests
7.2.6 Outdoor air
7.2.7 Water quality testing
(associated with HVAC systems)
7.2.8 Drinking water sampling and
analysis
7.2.9 Other tests
7.2.10 Facility inspection reports
7.2.11 Facility reinspections
7.3 Avoidance Procedures
7.3.1 Preventive operations,
maintenance, and policy
7.3.2 Designing healthy buildings
7.3.3 Managing IAQ risk within leases
Chapter 8. Technical Improvements Plan
Clive Shearer, Harlen E. Smith, and Alan
Pearlman, P.E.
8.1 Total Quality Management (TOM) Program
8.1.1 TOM-What it is
8.1.2 TQM-What it is not
8.1.3 Rewards to be reaped
8.1.4 How does TOM work?
8.1.5 Summary: What to do to keep TOM
on track
8.2 Value Improvement Program
8.2.1 Validation of value
8.2.2 Value engineering
8.2.3 Synergistic opportunities
8.2.4 Successful value engineering
8.2.5 Increase value
8.2.6 Value perceptions
8.2.7 Why does poor value occur?
8.2.8 Value engineering process
8.3 Energy Management Program
8.3.1 Overview
8.3.2 Mechanical systems
8.3.3 Control systems
8.3.4 Energy management programs
8.3.5 Chiller plant
8.3.6 Hot water reset
8.3.7 Lighting controls
8.3.8 Conclusions
Reference
Part 3 Equipment and Systems Operations and
Maintenance Procedures
Chapter 9. Equipment and Systems Operations
Procedures
Dennis E. Mulgrew
9.1 Equipment Inventory
9.1.1 Conditions assessment
9.1.2 Design assessment
9.2 Operational Requirements
9.2.1 Equipment startup and shutdown
9.2.2 Operational checks
9.2.3 Lighting
9.2.4 Relamping
9.2.5 Energy conservation
9.2.6 Use of demand control ventilation
9.3 Facility Management Tools
9.3.1 Energy management control system
(EMCS) operations
9.3.2 Emergency and extended FMS
operations
9.3.3 FMS service program
9.3.4 FM operating personnel
requirements
9.3.5 Remote control operating
requirements
Reference
Chapter 10. Fire Protection Systems
Paul Goldenberg
10.1 Fire Protection Systems
10.2 Basic Principles of Fire
10.3 Building Fire Prevention Codes
10.4 Fire Detection and Suppression
Systems
10.4.1 Types of detectors
10.4.2 Suppression systems
10.4.3 Portable fire extinguishers
10.5 Fire and Emergency Action Plans
Chapter 11. Electrical Equipment and System
Maintenance Procedures
Dana L. Green
11.1 Introduction
11.2 Electrical Safety
11.3 Insulation Resistance Measurements
11.4 Winding Turns Ratio Measurements
11.5 Power Factor and Dielectric-Loss
Measurements
11.5.1 Dielectric loss
11.5.2 Power factor
11.6 Motion Analysis of Circuit Breakers
11.7 Insulation and Insulators, General
11.8 Insulating Liquids
11.8.1 Sampling
11.8.2 Sample containers
11.8.3 Sampling location
11.8.4 Sampling procedures
11.8.5 Periodic tests
11.8.6 Other tests
11.9 Switchgear
11.9.1 Maintenance
11.9.2 Tests
11.10 Protective Relays
11.10.1 General
11.10.2 Construction
11.10.3 Types and device numbers
11.10.4 Maintenance
11.10.5 Tests
11.10.6 Cautions
11.11 Ground Fault Protection
11.11.1 Electrical tests
11.12 Ground Fault Circuit Interrupters
(GFCI)
11.13 Low-Voltage Molded (Insulated) Case
Circuit Breakers
11.13.1 Electrical tests, energized and
carrying load
11.13.2 Electrical tests, deenergized
11.14 Low-Voltage Air Circuit Breakers
11.14.1 Maintenance
11.14.2 Tests
11.15 Medium-Voltage Breakers
11.15.1 Air breakers
11.15.2 Maintenance
11.15.3 Tests
11.15.4 Vacuum breakers
11.15.5 Maintenance
11.15.6 Tests
11.15.7 Oil breakers
11.15.8 Maintenance
11.15.9 Tests
11.16 Switches
11.16.1 Maintenance
11.16.2 Tests
11.17 Fuses
11.17.1 Maintenance
11.17.2 Tests
11.18 Motor Control Centers and Starters
11.18.1 Maintenance, low-voltage units
11.18.2 Tests, low-voltage units
11.18.3 Maintenance, medium-voltage
units
11.18.4 Tests, medium-voltage units
11.19 Batteries and Battery Chargers
11.19.1 Batteries
11.19.2 Battery chargers
11.19.3 Maintenance of batteries
11.19.4 Tests
11.19.5 Maintenance of chargers
11.19.6 Tests
11.19.7 Cautions
11.20 Transformers
11.20.1 Power and distribution
transformers
11.20.2 Instrument transformers
11.20.3 Specialty transformers
11.20.4 Control transformers
11.20.5 Construction
11.20.6 Dry-type transformers
11.20.7 Liquid-filled transformers
11.20.8 Transformer insulating liquids
11.20.9 Transformer appurtenances
11.20.10 Maintenance, dry-type
transformers, as applicable
11.20.11 Tests of dry-type transformers
11.20.12 Maintenance of liquid-filled
transformers
11.20.13 Tests for liquid-filled
transformers
11.21 Voltage-Regulating Apparatus
11.21.1 Step voltage regulators and
load tap changers (LTC)
11.21.2 Induction-type voltage
regulators
11.21.3 Voltage-regulating relay system
11.21.4 Maintenance
11.21.5 Electrical tests
11.22 Cable and Wire
11.22.1 Maintenance
11.22.2 Testing
11.23 Rotating Machines
11.23.1 Introduction
11.23.2 Safety
11.23.3 Maintenance
11.23.4 Commutator, slip rings, and
brush maintenance
11.23.5 Alignment
11.23.6 Air gap measurement
11.23.7 Grounding straps
11.23.8 Tests
11.23.9 Synchronous motor tests
11.24 Surge Arresters
11.24.1 Maintenance
11.24.2 Tests
11.25 Grounding Systems and Equipment
Grounding
11.25.1 Grounding systems
11.25.2 Equipment grounding
11.25.3 Maintenance
11.25.4 Tests
11.26 Frequency of Performance
11.27 Personnel Qualifications
11.28 Tables of Values
References
Chapter 12. Outsourcing Considerations
Bernard T. Lewis and Paul S. Lewis
12.1 Recommended Tasks for Outsourcing
12.2 The Advantages and Disadvantages of
Outsourcing
12.2.1 Advantages
12.2.2 The disadvantages of outsourcing
12.3 Contract Services
12.4 Quality Control
12.5 Flexibility
12.6 Reduced Capital Expenditures
12.7 Employing Specialty Contractors
12.8 Selecting an Outsourcing Source
12.9 Judging Abilities of an Outsourcing
Firm
12.10 Responsibility for Outsource Firm
Administration and Control
12.11 Outsource Contract Administration
12.11.1 Negotiating the outsource
contract
12.11.2 Specification of services;
responsibility for communications;
supplies, materials, equipment, and
utilities
12.11.3 Certified outsource firm
personnel to be used
12.11.4 Scheduling work and/or
reporting requirements
12.11.5 Supervision of outsourcing
agreement
12.11.6 Conclusion
References
Chapter 13. General Cleaning, Solid Waste and
Recycling
Steve Sadler and Paul Zeski
13.1 General
13.2 Types of Cleaning
13.3 Cleaning Program
13.4 Staffing
13.5 Job Descriptions
13.6 Quality Control
13.7 Waste Management Program
References
Chapter 14. Landscaping Services
Carleen M. Wood-Thomas
14.1 General Responsibilities of the
Contractor
14.2 Selecting a Contractor and the
Bidding Process
14.3 Lawn Maintenance
14.3.1 Mowing and trimming
14.3.2 Weed control and pests
14.3.3 Fertilization
14.3.4 Dethatching and aeration
14.3.5 Overseeding
14.4 Maintenance of Trees, Shrubs, and
Other Plantings
14.4.1 Mulch and weed control
14.4.2 Pruning
14.4.3 Fertilization
14.4.4 Cleanup
14.5 Pest Management
14.6 Watering
14.7 Seasonal Color
14.8 Quality Control
References
Chapter 15. Elevator and Escalator Equipment
and Systems Maintenance and Repair Services
Ronald D. Schloss
15.1 Introduction
15.2 Operating Instructions
15.2.1 Elevators
15.2.2 Freight elevators
15.2.3 Hand elevators
15.2.4 Hand-operated dumbwaiters
15.2.5 Hand- and power-operated
dumbwaiters
15.2.6 Wheelchair lifts
15.2.7 Escalators and moving walks
15.2.8 ADA signage (Americans with
Disabilities Act)
15.2.9 Additional signage
15.2.10 Equipment identification signs
15.3 Maintenance of Equipment
15.3.1 Definitions and terminology
15.3.2 Contracted maintenance
15.3.3 In-house maintenance
15.3.4 Removing equipment from service
15.4 Monitoring Equipment Performance
15.4.1 What to monitor
15.4.2 Callback and downtime performance
15.5 Monitoring Maintenance Performance
15.6 Improving Safety and Limiting
Liability
15.7 Modernization of Equipment
15.7.1 Why, when, and what to modernize
15.7.2 How to select a modernization
contractor
References
Chapter 16. Water Treatment Services
Arthur J. Freedman
16.1 Facility Water Systems
16.1.1 Air-conditioning systems
16.1.2 Heating systems
16.1.3 Humidification systems
16.1.4 Potable water systems
16.1.5 Principles of water treatment
16.2 Obtaining Water Treatment Services
16.2.1 Contracted services vs. in-house
water treatment
16.2.2 Full-service water treatment
16.2.3 Support service water treatment
16.2.4 The role of consultants in
contracted water treatment services
16.3 Installing a New Water Treatment
Program
16.3.1 Selecting a water treatment
vendor
16.3.2 Water treatment specifications
16.4 Managing a Facility Water Treatment
Program
16.4.1 Service programs
16.4.2 Evaluating water treatment
program performance
16.4.3 Cleaning water system equipment
and piping
References
Chapter 17. Utilities Infrastructure Systems
Robert L. Camperlino
17.1 Introduction
17.2 Steam and Hot Water Production
17.2.1 Boiler types
17.2.2 Basic design
17.2.3 Packaged units or field erected
17.2.4 Steam or hot water generation
17.2.5 Operating pressure
17.2.6 Type of fuel
17.2.7 Chemical water treatment
17.3 Chilled Water Production
17.3.1 Chiller types
17.3.2 Efficiency
17.3.3 Refrigerants
17.3.4 Cooling towers
17.3.5 Chiller and cooling tower water
treatment
17.4 Support Equipment
17.4.1 Pumps
17.4.2 Condensers
17.4.3 Piping, valves, traps, insulation
17.5 Cost of Utilities
17.5.1 Cost of purchasing electricity
17.5.2 Cost of producing steam
17.5.3 How to estimate building
component heating costs
17.5.4 How to estimate building
component cooling costs
17.5.5 How to evaluate energy cost
savings
17.6 Energy Conservation Measures
17.6.1 Thermal storage
17.6.2 Ice storage
17.6.3 Variable speed drives
References
Part 4 Facilities Emergency Preparedness
Chapter 18. Facilities Emergency Preparedness
Richard P. Payant
18.1 Why Emergency Response Preparedness?
18.2 Types of Emergencies
18.3 Assess Vulnerabilities
18.4 Support Services
18.5 Specific Procedures
18.6 Start Point
18.7 Organization
18.8 Concept of Operation
18.9 Command and Control
18.10 Emergency Operations Center
18.11 Responsibilities
18.11.1 Facility manager's
responsibility
18.11.2 Security responsibilities
18.12 Communications
18.13 Mitigation
18.13.1 Mitigation factors
18.14 Damage Assessment
18.14.1 Damage assessment team
composition
18.14.2 Damage assessment report
18.14.3 Damage assessment team
responsibilities
18.14.4 Damage assessment information
sources
18.14.5 Damage assessment logistics
considerations
18.15 Information for First Responders
18.16 Facility "First Responders"
18.17 Recovery
18.17.1 Recovery-General concept
18.17.2 Recovery-Facilities restoration
18.17.3 Recovery-Administration and
logistics
18.18 Training
18.18.1 Training objectives
18.18.2 Team training
18.18.3 First responders training
18.19 Facility Intelligence
18.20 Summary
References
Part 5 Capital Investment
Chapter 19. Capital Investment
Daniel C. Harrison and Richard P. Payant
19.1 Introduction
19.2 General
19.3 Cost Accounting
19.3.1 Incremental costs
19.3.2 Opportunity costs
19.3.3 Future costs
19.3.4 Traceable costs
19.3.5 Direct and indirect costs
19.3.6 Sunk costs
19.3.7 Book costs
19.3.8 Replacement costs
19.3.9 Fixed costs
19.4 Interest
19.4.1 Simple interest
19.4.2 Compound interest
19.5 Depreciation
19.5.1 Depreciation accounting
19.6 Comparison of Alternatives
19.6.1 Equivalent annual cost
19.6.2 Present worth
19.6.3 Rate of return
19.6.4 Salvage value
19.6.5 Benefit-cost ratio
19.7 Economic Studies
19.7.1 Profit
19.7.2 Ratio of income and investment
19.8 Income
19.9 Plan for Economic Analysis
19.9.1 Creative step
19.9.2 Definitive step
19.9.3 Conversion step
19.9.4 Decision step
19.10 Estimates in Economic Analysis
19.11 Capital Investment
19.11.1 Criteria and strategy for
capital investment
19.11.2 Capacity of facility to perform
its mission
19.11.3 Economic opportunity
19.11.4 Economic analysis of capital
expenditures
19.12 Life Cycle Costing
19.13 Sources of Information and
Assistance
19.14 Justification and Requirements
19.15 Economic Evaluation and Intangibles
19.16 Validation
Glossary G.1
Index I.1
