1. SNS Integrated Maintenance Management Program

2. 2 Presentation name Presentation_name Goals The goals for Accelerator systems include: 4500 Hours of neutron production beam, at greater than 90% availability at or close to the nominal power delivery capacity of the SNS. As the funding landscape shifts, achieving these goals will become more challenging. Increasingly greater demands are being placed on facility even as those staff are becoming leaner and in some cases less experienced due to retirements. As time passes, conditions change. Older equipment becomes obsolete and new equipment is added on a continuous basis. As a result, facilities are being operated and maintained under continually changing conditions. These changes will produce a new dynamic for our organization that adds to the facility maintenance challenges that we will face. Our goals can be met in this challenging environment by developing best practices associated with an Integrated Maintenance Program structure and functionality. We must develop a maintenance processes that identifies causes of potential equipment failures, effectively monitors and assesses equipment condition, and proactively plans for equipment maintenance. This organization will more effectively utilize our staff by increasing their proficiency by applying standard processes, facilitating peer collaboration, completing databases to support condition- based maintenance, and documenting case histories. Vision The vision of the SNS Integrated Maintenance Management Program is an efficient, effective, reliable science facility throughout the lifetime of the SNS, currently expected to be ~40 years.

3. 3 Presentation name Presentation_name SNS Integrated Maintenance Program The SNS Integrated Maintenance Program is a facility-wide program for maintaining and improving SNS Facilities in a cost-effective manner over the lifetime of the facility. The core of this program is a Reliability Centered Maintenance program. It is surrounded by a number of linked Management Information Systems (MIS) and SNS specific Policies and Procedures using applicable industrial standards. These MIS systems include; – A Computerized Maintenance Management System (CMMS) – A Document Control System (DCS) linked to the CMMS – A Work Request/Planning/Scheduling System linked to the CMMS – A Beamtime/Downtime Tracking System – A Performance Metrics Reporting System – A Reliability (RAMI) Modeling System – A Spares Plan – An Equipment Obsolescence Plan – A process for driving continued improvement in Equipment Design and Operation – A Configuration Control System to keep you from doing STUPID THINGS Enablers

4. 4 Presentation name Presentation_name Major Components SNS Integrated Maintenance Program RAMI Model Spares Plan Reactive Maintenance < 10% Predictive Maintenance 45-55% Preventative Maintenance 25-35% Reliability Centered Maintenance Testing and Inspection Equipment Obsolescence Plan Performance Metrics CMMS Goals FMEA Equipment Design Considerations Equipment Operations Considerations Upgrades and New Equipment /Systems Fault Reporting Work Planning - Scheduling Document Control

5. 5 Presentation name Presentation_name CMMS Equipment Tracking Inventory Control Work Execution Work Planning Equipment StatusPosition-Location History Asset History Work Requests/Authorizations Work Prioritization and Scheduling Resource Allocation and Scheduling Automated Time-Based PMs Work Documentation Post Maintenance Testing Equipment Swaps Inspections/Testing Based PMsAutomated Meter-Based PMs Spares and Parts ManagementWarranty Information Tracking Equipment Repair Maintenance Costs TrackingMaintenance Hours Tracking

6. 6 Presentation name Presentation_name Analysis Identifies Problem Areas Fault Reporting Performance Metrics Operations Administration System (OAS) Shift Reports Electronic Logbook (E-Log) E-Log entries and OAS Downtime are reported. Work Orders are created in the CMMS and entered in the E-Log. Downtime linked to Work Order Number in the OAS is reported in the Metrics Downtime and Trip Rates are evaluated in the Weekly Machine Health Report, The trend from the past week, 2 weeks ago and 3 week ago. Weekly Metrics and Machine Health Report List of Machine “Issues” Work Requests Failure precursors are identified by increased trip rates

7. 7 Presentation name Presentation_name Goals Performance Metrics RAMI Model Equipment Design Considerations New/Improvements Equipment Operations Considerations Evaluation Process Drives Improvement Performance Metrics are evaluated against Goals and compared with expectations from the RAMI model. Opportunities for enhanced performance are identified and used to drive change in design or operations. Evaluation

8. 8 Presentation name Presentation_name Reactive Maintenance < 10% Predictive Maintenance 45-55% Preventative Maintenance 25-35% Reliability Centered Maintenance Testing and Inspection FMEA Industrial Standards for Reliability Centered Maintenance (RCM) References: DOE EERE O&M Best Practices Guide Rev. 3 NASA RCM Guide 2008 Accelerator Systems have more Reactive Maintenance due to the high percentage of digital electronic systems which fail with no precursor events.

9. 9 Presentation name Presentation_name Types of Maintenance Reactive Maintenance Reactive maintenance is basically the “run it till it breaks” maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. – Advantages Low initial cost. Less staff. – Disadvantages Increased unplanned downtime of equipment. Increased labor cost due to overtime needed for call-in repairs Possible secondary equipment or process damage from equipment failure. Inefficient use of staff resources.

10. 10 Presentation name Presentation_name Preventive Maintenance Preventive maintenance can be defined as follows: Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level. Advantages Cost effective in many capital-intensive processes. Flexibility allows for the adjustment of maintenance periodicity. Increased component life cycle. Energy savings. Reduced equipment or process failure. Estimated 12% to 18% cost savings over reactive maintenance program. Disadvantages Catastrophic failures still likely to occur. Labor intensive. Includes performance of unneeded maintenance. Potential for incidental damage to components in conducting unneeded maintenance.

11. 11 Presentation name Presentation_name Predictive Maintenance Predictive maintenance can be defined as follows: Measurements that detect the onset of system degradation (lower functional state), thereby allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability. Advantages Increased component operational life/availability. Allows for preemptive corrective actions. Decrease in equipment or process downtime. Decrease in costs for parts and labor. Improved worker and environmental safety. Improved worker morale. Estimated 8% to 12% cost savings over preventive maintenance program. Disadvantages Increased investment in diagnostic equipment. Increased investment in staff training. Savings potential not readily seen by management.

12. 12 Presentation name Presentation_name Reliability Centered Maintenance Reliability centered maintenance (RCM),RCM is a systematic approach to evaluate a facility’s equipment and resources to best mate the two and result in a high degree of facility reliability and cost-effectiveness The RCM methodology recognizes that 1.all equipment in a facility is not of equal importance to either the process or facility safety. 2.equipment design and operation differs and that some will have a higher probability to undergo failures from different degradation mechanisms than others. It also approaches the structuring of a maintenance program recognizing that a facility does not have unlimited financial and personnel resources and that the use of both need to be prioritized and optimized

13. 13 Presentation name Presentation_name Advantages Can be the most efficient maintenance program. Lower costs by eliminating unnecessary maintenance or overhauls. Minimize frequency of overhauls. Reduced probability of sudden equipment failures. Able to focus maintenance activities on critical components. Increased component reliability. Incorporates root cause analysis. Disadvantages Can have significant startup cost, training, equipment, etc. Savings potential not readily seen by management

14. 14 Presentation name Presentation_name Reliability Centered Maintenance Hierarchy Reactive Element Applications Preventive Element Applications Predictive Element Applications Small parts and equipmentEquipment subject to wearEquipment with random failure patterns Non-Critical or Redundant Equipment Consumable equipmentCritical equipment Equipment unlikely to failEquipment with known failure patterns Equipment not subject to wear Electronics which give little or no warning of failure Manufacturer recommendationsSystems which failure may be induced by incorrect preventive maintenance

15. 15 Presentation name Presentation_name Where are we and what are the Problems? Initially all maintenance was Reactive After much effort we had a mix of Reactive and Preventative We are moving as much as we can to Predictive – Rotating Systems Water Pumps, Motors Compressors Cryo-Compressors However this is a long, slow process and only happens after the System Engineers become convinced that it saves time, money and people.

16. 16 Presentation name Presentation_name What about the Integrated Maintenance Management System? We have all the various bits and pieces – A Computerized Maintenance Management System (CMMS) – A Document Control System (DCS) linked to the CMMS – A Work Planning and Scheduling System in the CMMS – A Beamtime/Downtime Tracking System (OAS) – A Performance Metrics Reporting System (highly manual) – A Reliability (RAMI) Modeling System (Stand-Alone System) – A Spares Plan ( Not Enforced) – An Equipment Obsolescence Plan (DRAFT) – A process for driving Continued Improvement in equipment design and operation (the part that we do really well)

17. 17 Presentation name Presentation_name Unfortunately most of the links between system are highly manual, little automation. This makes extracting information a time consuming process and it is only done for systems that really “stick out” in the metrics (high failure rate and/or high related downtime). We are creating “Reports” in the CMMS that give MTBF – It is only as good as the data that went in (GIGO!!!) – Lots of early work done against “General Assets” – Still a “Hand Comparison” with the RAMI Model So, in the words of recent Management Gurus the word “Integrated” is not a Core Value but an Aspirational Value.

18. 18 Presentation name Presentation_name Where to go next? Pick the low hanging fruit first: – Get as many high cost, long lead time systems into Predictive measurements as we can (klystrons) – Monitor MTBF and MTTR as a function of installed operating hours – Extract the failure distributions and keep them updated to detect the onset of terminal mortality – Put Spares in Model, extract MTTSO (mean time to stock outage) and determine how close to the edge we dare to operate – Use our Obsolescence program to Upgrade by Spares, assuming backward compatibility (get onboard with major supplier and follow their upgrade path)