maintenance specificities in the cern cooling and ventilation g roup
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Maintenance Specificities in the CERN Cooling and Ventilation G roup . Asset and Maintenance Management Workshop CERN, 13-15 November 2013. I. El Hardouz, U. Epting , S. Poulsen , G. Peon (CERN EN/CV). Summary. Definitions and Acronyms Introduction to EN/CV Overview of EN/CV Maintenance - PowerPoint PPT PresentationTRANSCRIPT
Maintenance Specificities in the CERN Cooling and Ventilation Group
Asset and Maintenance Management Workshop CERN, 13-15 November 2013
I. El Hardouz, U. Epting, S. Poulsen, G. Peon (CERN EN/CV)
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Summary
โข Definitions and Acronymsโข Introduction to EN/CVโข Overview of EN/CV Maintenanceโข CMMS in EN/CVโข Key Performance Indicatorsโข Meter Readingsโข Conditional Maintenanceโข Summaryโข Conclusions
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Definitions and Acronyms
โข Positionโข Hierarchical structure
โ Parentโ Child
โข MP: Maintenance Planโข PM: Preventive Maintenanceโข CM: Corrective Maintenanceโข WO: Work Order
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Equipment Structure
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Introduction to EN/CV
The CV group is responsible for the CERN Cooling and Ventilation
installations:
DESIGN WORKS OPERATION MAINTENANCE
ACCELERATORS DETECTORS EXPERIMENTAL AREAS
COMPUTER CENTER
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Introduction to EN/CV
HVAC:
TunnelExperimental cavernsService cavernsPressurized safe areasSurface โmachineโ buildingsSmoke and Gas Extraction Systems
Water Systems:
Primary waterDemineralised waterChilled waterMixed waterReject waterSanitary waterFire fighting water
Compressed air systems
ElectricityControl and supervision systems
A total of 76000
pieces of equipment
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Cooling and distributionCooling towers (450 MW) 22Chilled water production : 6-12oC (73 MW) 35Cooling plants (raw water, demineralized water, C3F8, C6F14) 150Distribution Pipework 800 kmTotal water consumption 5'400 m3/h
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Equivalent to 10% consumption Geneva
Canton
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Ventilation, Fluid SystemsHVAC 1โ500 units
from 2โ000 to 120โ000 m3/h per unitFire fighting systems 800 pointsCompressed air 14 installations
distribution network 200 kmDemineralised water production 20 m3/h - 0.1 ฮผS/cm
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Overview of EN/CV Maintenance
โข The general activities are covered by just two contractors โข Other particular activities are assigned to specialised
contractors, i.e. water treatmentโข Their work is divided in geographical areas
โ PS complex plus 50% of the LHC installationsโ SPS complex plus 50% of the LHC installations
โข Stand by interventions:โ PS, SPS: Contractorsโ LHC, CERN Computing Centre: CERN
โข Maintenance Budget of 6MCHF/yrโข Asset Value of 600MCHF13/Nov/2013
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CV specifies a period in which the works have to be carried
out
CV specifies actual dates for the work according to the CERN overall planning
Non
YesThe CMMS creates a Preventive WO
according to the MP The contractor plans the work
in CMMS
Technical Check Correct?
Verification of data and billing
codes in the WOCorrect?
WO taken into account by the
system for payment
Ready for payment
Yes
Yes
Works carried out in the installation
Non
Critical installation?
CV approves the date?
Non
Request for the material
Yes
Non
Contractor enters comments and billing
codes into the WO
Comments by CV for explanation of
rejection
Safety assessment and
notifications
Comments by CV for explanation of
rejection
Organisation of the Preventive Maintenance
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Preventive MaintenanceMaintenance Plans
โข MPs generates WOs at the level of the Parentโข The WOs point to Maintenance Procedures
according to the equipment installed within the Parent
โข The MPs automate provisional WO start and end dates
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Alarm to the CCC
Discovery by CV operator Creation of a WO (indicates date of intervention)
E-mail and SMS sent to the CV operators and contractor
Creation of a WO for stand-by service
Intervention by the corrective team
Breakdown solved
Oui
Parts available?
Breakdown
Acceptance of the WO by contractor
Non
Technical check Correct?
Verification of data and billing
codes in the WO
Non
Correct?
WO taken into account by the
system for payment
Ready for payment
Yes
Yes
Intervention of the corrective team
Oui
Non
Entry of the WO comments and
billing codes
Comments in WO to explain rejection
Comments in WO to explain
rejection
Outside working hours?
Breakdown solved
access possible?
Magasin process demand
Request / Wait
Non Non
Entry of the WO
comments and billing
codes
Organisation of the Corrective Maintenance
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CMMS in EN/CVโข CV utilizes mainly the following modules in
INFOR EAMEquipment
AssetsPositionsPartsStructure
StoresSpare PartsPick TicketsReservationRequisitionPurchase ordersParts labellingMinimum stocks
WorksWork requests Work orders (WO)Maintenance plansInspectionsMeter readings
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Information in the WOs
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Dates in WOsFilled by the system
Event date: date of WO creation
Filled by CV personnelRequested start dateRequested end date
Filled by contractorsโ personnelSchedule start dateSchedule end dateActual start and end datesRequest and delivery of spares
Other Information:Filled by CV personnel
Information to assess the workContact personParticular safety issues
Filled by contractorsโ personnelยซAssigned toยปBooked hours for a particular employee and dayDescription of the work doneSpare parts usedTests carried outโฆ
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Main KPI: Contractor Performance๐พ๐๐ผ 3= ๐ถ๐๐๐๐๐๐ก๐๐ ๐๐๐๐๐
๐๐๐ก๐๐๐๐ .๐๐ ๐ ๐๐๐ข๐๐ ๐ก๐๐ ๐๐๐๐๐
๐พ๐๐ผ 5= ๐ถ๐๐๐๐๐๐ก๐๐ ๐๐๐๐๐ ๐๐๐ก๐๐๐๐ .๐๐ ๐ ๐๐๐๐๐๐๐๐ฆ ๐ถ๐๐๐ก๐๐๐๐ก ๐๐ ๐๐๐๐๐
๐พ๐๐ผ 7=๐ท๐๐๐๐ฆ ๐๐๐๐๐๐ฃ๐๐๐ก๐๐ฃ๐๐๐๐๐๐ก๐๐๐๐๐๐(๐๐๐ฆ๐ )
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๐พ๐ ๐ผ 10=๐๐ .๐๐ ๐๐๐๐๐๐๐๐๐ฃ๐๐๐๐
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Main KPIs: Equipment Condition
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๐พ๐๐ผ 13=๐๐๐ 10๐๐๐ ๐๐ก๐๐๐๐ ๐๐๐๐๐ก๐๐๐๐ถ๐๐พ๐๐ผ=๐๐ .๐๐ ๐๐๐ ๐๐๐๐ถ๐๐ข๐ ๐๐ถ๐๐๐
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Main KPIs : Reactivity
๐พ๐๐ผ 15=๐ท๐๐๐๐ฆ ๐๐๐๐ s๐ฃ๐๐๐๐๐๐๐๐ก๐๐๐๐พ๐๐ผ 17=๐๐๐๐ ๐พ๐๐ผ 18=๐๐๐๐ถ
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Main KPIs : Overall performance
๐พ๐๐ผ 5= ๐ท๐๐๐๐ฆ ๐๐๐๐ (๐๐๐ฆ๐ )๐๐๐ก๐๐๐๐ .๐๐ ๐๐๐ฆ๐ ๐๐๐ก๐ค๐๐๐๐ก๐ค๐ ๐๐
๐พ๐๐ผ 7=๐๐ .๐๐๐ ๐ค๐๐๐ก๐๐๐ ๐๐๐ ๐๐๐๐๐ ๐
๐พ๐๐ผ 1= ๐ถ๐๐๐๐๐๐ก๐๐๐ถ๐๐๐๐ ๐๐๐ก๐๐ ๐๐.๐๐ ๐ถ๐๐๐๐๐๐ก๐๐๐๐๐
๐พ๐๐ผ 11=๐๐ .๐๐๐ ๐ค๐๐๐ก๐๐๐ ๐๐๐ ๐ ๐๐๐๐๐๐๐๐ก๐
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Examples of two KPIs over time
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Meter Readings in the CV groupโข Meter readings for different equipment
โ Air Compressorsโ Trane Chillers
โข Frequencyโ Different intervals: e.g. weekly, twice per yearโ Configured via Infor EAM PM Schedules
โข Visualizationโ Infor EAM Custom Tab: โInspections & Readingsโ
โข Tools for data entryโ GS-ASE Infor EAM Mobile (Psion handheld)โ EN-CV smartphone application
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Meter Readings: CV Smartphone Application
โข Webpage application optimised for smartphones
โข It organizes the data collection by PM Schedule (can comprise equipment of different Classes)
โข No investment required for proprietary equipment and can be on operators personal device (Bring-Your-Own-Device)
โข It can also be used from any platform with a Web browser (including Psion Ikon)
โข It works off-line in areas without GSM/WiFiโข It is very responsive
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Meter readings: Ex. Historical data of chiller FCK-00030
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Mechanical revision 40000h and cleaning of a chiller in bldg. 355, 378
โฆ before and after cleaning bldg. 378
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Conditional Maintenance: Vibration analyses
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Conditional Maintenance: Vibration analyses
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Conditional Maintenance: Vibration analyses
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Conditional Maintenance: Vibration analyses
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Summaryโข EN/CV utilises the main modules of INFOR EAMโข Information entered by the System, CV staff and
Maintenance contractors is crucial to assess the different actors in maintenance
โข CV makes use of tailored made KPI to pinpoint weak and strong points in the Maintenance activities
โข Particular Meter Readings are valuable information to trigger conditional maintenance in some equipment such chillers and compressors
โข A specific project has been made for Conditional Maintenance based on Vibration measurements
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Conclusionsโข Structure of equipment it reduces the intervention time for all
the maintenance participantsโข KPIs, utilised to better monitor the Maintenance Activity and
plants condition to:โ Support the decisions by the CERN managementโ Take actions by Stores and Operationsโ Manage of Contractorsโ Repair and improve the installations
โข Meter readingsโ Faster data entry and interpretation of resultsโ Clearer vision of the equipment utilization over time
โข Vibration analysisโ Detect risk and allow for intervention before breakdown
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THANK YOU FOR YOUR ATTENTION!!
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