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
β’ Definitions and Acronymsβ’ Introduction to EN/CVβ’ Overview of EN/CV Maintenanceβ’ CMMS in EN/CVβ’ Key Performance Indicatorsβ’ Meter Readingsβ’ Conditional Maintenanceβ’ Summaryβ’ Conclusions
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Definitions and Acronyms
β’ Positionβ’ Hierarchical structure
β Parentβ Child
β’ MP: Maintenance Planβ’ PM: Preventive Maintenanceβ’ CM: Corrective Maintenanceβ’ 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 βmachineβ 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 1β500 units
from 2β000 to 120β000 m3/h per unitFire fighting systems 800 pointsCompressed air 14 installations
distribution network 200 kmDemineralised water production 20 m3/h - 0.1 ΞΌS/cm
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Overview of EN/CV Maintenance
β’ The general activities are covered by just two contractors β’ Other particular activities are assigned to specialised
contractors, i.e. water treatmentβ’ Their work is divided in geographical areas
β PS complex plus 50% of the LHC installationsβ SPS complex plus 50% of the LHC installations
β’ Stand by interventions:β PS, SPS: Contractorsβ LHC, CERN Computing Centre: CERN
β’ Maintenance Budget of 6MCHF/yrβ’ 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
β’ MPs generates WOs at the level of the Parentβ’ The WOs point to Maintenance Procedures
according to the equipment installed within the Parent
β’ 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/CVβ’ 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 contractorsβ 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 contractorsβ personnelΒ«Assigned toΒ»Booked hours for a particular employee and dayDescription of the work doneSpare parts usedTests carried outβ¦
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Main KPI: Contractor PerformanceπΎππΌ 3= πΆππππππ‘ππ πππππ
πππ‘ππππ .ππ π πππ’ππ π‘ππ πππππ
πΎππΌ 5= πΆππππππ‘ππ πππππ πππ‘ππππ .ππ π ππππππππ¦ πΆπππ‘ππππ‘ ππ πππππ
πΎππΌ 7=π·ππππ¦ ππππππ£πππ‘ππ£ππππππ‘ππππππ(πππ¦π )
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πΎπ πΌ 10=ππ .ππ πππππππππ£ππππ
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Main KPIs: Equipment Condition
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πΎππΌ 13=πππ 10πππ ππ‘ππππ πππππ‘ππππΆππΎππΌ=ππ .ππ πππ ππππΆππ’π ππΆπππ
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Main KPIs : Reactivity
πΎππΌ 15=π·ππππ¦ ππππ sπ£ππππππππ‘ππππΎππΌ 17=ππππ πΎππΌ 18=ππππΆ
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Main KPIs : Overall performance
πΎππΌ 5= π·ππππ¦ ππππ (πππ¦π )πππ‘ππππ .ππ πππ¦π πππ‘π€ππππ‘π€π ππ
πΎππΌ 7=ππ .πππ π€πππ‘πππ πππ πππππ π
πΎππΌ 1= πΆππππππ‘πππΆππππ πππ‘ππ ππ.ππ πΆππππππ‘πππππ
πΎππΌ 11=ππ .πππ π€πππ‘πππ πππ π ππππππππ‘π
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Examples of two KPIs over time
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Meter Readings in the CV groupβ’ Meter readings for different equipment
β Air Compressorsβ Trane Chillers
β’ Frequencyβ Different intervals: e.g. weekly, twice per yearβ Configured via Infor EAM PM Schedules
β’ Visualizationβ Infor EAM Custom Tab: βInspections & Readingsβ
β’ Tools for data entryβ GS-ASE Infor EAM Mobile (Psion handheld)β EN-CV smartphone application
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Meter Readings: CV Smartphone Application
β’ Webpage application optimised for smartphones
β’ It organizes the data collection by PM Schedule (can comprise equipment of different Classes)
β’ No investment required for proprietary equipment and can be on operators personal device (Bring-Your-Own-Device)
β’ It can also be used from any platform with a Web browser (including Psion Ikon)
β’ It works off-line in areas without GSM/WiFiβ’ 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
β¦ 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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Summaryβ’ EN/CV utilises the main modules of INFOR EAMβ’ Information entered by the System, CV staff and
Maintenance contractors is crucial to assess the different actors in maintenance
β’ CV makes use of tailored made KPI to pinpoint weak and strong points in the Maintenance activities
β’ Particular Meter Readings are valuable information to trigger conditional maintenance in some equipment such chillers and compressors
β’ A specific project has been made for Conditional Maintenance based on Vibration measurements
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Conclusionsβ’ Structure of equipment it reduces the intervention time for all
the maintenance participantsβ’ KPIs, utilised to better monitor the Maintenance Activity and
plants condition to:β Support the decisions by the CERN managementβ Take actions by Stores and Operationsβ Manage of Contractorsβ Repair and improve the installations
β’ Meter readingsβ Faster data entry and interpretation of resultsβ Clearer vision of the equipment utilization over time
β’ Vibration analysisβ Detect risk and allow for intervention before breakdown
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THANK YOU FOR YOUR ATTENTION!!
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