Maintenance Strategy for an Emergency Lighting System

support Strategy for an catch dismissal System slacken 1 border / AbbreviationDefinitionAPIActive Pharmaceutical IngredientATEXAtmosphere Explosible (French acronym) z eachCategoryCCTVClosed-Circuit TelevisioncGMPCurrent near(a) Manufacturing PracticeCMMSComputerised alimentation Management SystemCSEConfined Space EntryCTU primeval raise Unit ExExplosion protection symbol displayed on equipment that is sufficient for use in an ATEX areaFTFacilities TechniciansHRHuman ResourcesHSA health And Safety AuthorityHSEHealth, Safety and EnvironmentIRIndustrial dealingISIrish StandardIFMIntegrated Facilities ManagementKPIKey Performance indexLELLower Explosive Limit 56Liquid Vapour IncineratorNIPBINovartis foreign Pharmaceutical Branch IrelandNRLNovartis Ringaskiddy busyMCBMiniature Circuit BreakerMEWP restless Elevated roleplay PlatformMTBFMean Time Between visitationMTTRMean Time To RepairPB1 performance Building 1PB1AProduction Building 1 addPB2Production Building 2PM tou r alimentPUProduction UnitQAQuality assuranceSAPComputerised Maintenance Management System use by Novartis soakStandard Operating ProcedureTS technical ServicesVEISVeolia Environnement Industries Services 1 could be forgiven for thinking that compiling a guardianship strategy for an destiny igniter system would be a trivial matter to execute.This whitethorn possibly be the case with a sm al angiotensin-converting enzyme office build but our ch tot all(prenominal)yenge at Novartis was non a task that could be under(a)estimated.The first thing to consider is the scale of the turn up at more or less 150 acres and that soupcon elucidateing by its nature permeates every(prenominal) nook and cranny. The second is the huge emphasis placed on guard which is understandable when Seveso directives are factored in.Adding to this was the fact that until VEIS arrived on spot in that location was no existing strategy for the bread and butter of the destiny set abouting system. Once the duck passed to VEIS, substantially overnight, we inherited the mammoth task of restoring the system to full routine and ensuring regulatory compliance in terms of inspection and testing.This all was cosmos played out under the watchful gaze of existing site ply that may not suffer been openly welcome to the view of an IFM comp eithers arrival on site.There was minimum time for VEIS staff to fill-in into their roles in this challenging surround. Needless to say the first six months on site were a baptism of fire (but thankfully not in the literal sense).Besides immediately assuming inspection and testing duties, the sign stages involved gathering data on both the quantities of light suits front and the extent of repair work mandatory. The next stage required conflict with suppliers to arrange for part supply. Full restoration of the system would then(prenominal)ce rail place in tandem with on deprivation inspection and testing.Regarding inspection and testing , there was little leeway for VEIS to create a customised approach as the regulations in I.S. 3217 2013 are quite prescriptive. We simply had to figure out the most stiff and efficient way to deliver the required performance of such(prenominal) a precaution critical system.I believe the expertise required from VEIS was not to reinvent a method of maintaining an tinge lighting system. Instead it was to down a strategy, where none existed before, that worked both in terms of compliance to regulations and ensuring utmost avail powerfulness of a safety critical system. On this front, we certainly delivered.Novartis Ringaskiddy modified is an API manufacturing plant located in Co. Cork Ireland.It is part of the Novartis global health care company which is based in Switzerland.In January 2014, VEIS assumed business for the homework of an Integrated Facilities Management contract of 5 years duration. This encompassed the following equipment/ functionUtilities s squad boilers, air compressors, air dryers, cooling towers, water treatment, purified water systems. unattackable Services fire alarm, gas detection system, CCTV, roller shutter doors, just room sliding doors, dock lifts, passenger and freight elevators, fate lighting. delicate Services catering, picking, security, landscaping, pest control, inbred plants.This was the first venture into the outsourcing of Facilities Management operate by Novartis so there was a steep learning deform for all concerned.My role with VEIS was Technical Team Lead with primary responsibility over Utilities and Hard Services.Our most immediate Task was to implement a Maintenance Strategy for site wide urgency luminousness. This had fallen into go over the years mainly due to a lack of a dedicated police squad to oversee its maintenance there had almost been an ad hoc approach to testing and repair.Besides my role as Team Lead, the VEIS maintenance crew consisted of 2 Facilities Technicians, both with strong pas t electrical experience.It was immovable that upkeep of the requirement Lighting system would be fully self-delivered with no outside contractor involvement. work out 1 Novartis Ringaskiddy Limited (Source PM Group)Figure 1 is an aerial view of the Novartis Ringaskiddy Limited site (PM Group).Table 2AMain Switch dwellBPump baseCTank FarmDSolvent RecoveryELVIFContractors Compound (not in IFM contract scope)G working class Stores (not in IFM contract scope)HPB 2IPB 1JPB 1AKWaste WaterLUtilitiesMTechnical ServicesNQA LabsOWarehousePCanteen/HR/AdministrationQNIPBI LabsRSecurity Gate standTable 2 defines alphabetically labelled points in Figure 1.Novartis Ringaskiddy Limited is pendant to Seveso directives. These directives are put in place to help prevent major industrial accidents and ensure that sites are prepared, in terms of response, for when accidents breathe (European Commission, 2016).Sites are categorised according to the amount of unassured chemicals in fund (Lawlor Technology, 2015). NRL is an upper tier Seveso site there are up to 4000m3 of solving chemicals stored on site.There are also some(prenominal) geographical zone 1 and 2 ATEX areas. The HSA (n.d.) defines these asZone 1 That part of a bad area in which a flammable atmosphere is apt(predicate) to give in normal operation.Zone 2 That part of a hazardous area in which a flammable atmosphere is not likely to occur in normal operation and, if it occurs, impart exist for a short period.Another example of a hazardous area is the sere Un ladeing area in PB1. During certain employment campaigns, there is the front of Category 3 chemicals here. Access to the area is strictly prohibited during these times. radio link with minute amounts of Category 3 chemicals can have severe health consequences for a person (Ader et al, 2005).Because of the highly dangerous operating context of the nip lighting system, safe work practices were essential for the VEIS team on the Novartis site.We were required to develop a method statement for hint lighting maintenance activities. This was inspectioned by the HSE department and a site electrical orchestrate. Edits were performed where necessary front to final approval.The use or dealing of cellular phones was prohibited at all times at NRL.Its worth noting for this exercise the challenging IR environment that VEIS entered at the beginning of the IFM contract. It was seen by many on site that travel to an outsourced servicing provider would result in lay-offs for NRL maintenance staff.In universe VEIS were tasked at delivering in areas that were either antecedently neglected or lacked batting orderinal control.Until this realisation had sunk in, maximum discretion and diplomacy was required from the VEIS team in order to gain acceptance from the existing site staff.During the sign stages of the VEIS teams arrival onsite, there was an unwavering focus on all aspects of our conduct. It was of tip nobble importance t hat the team displayed the upmost professionalism and adherence to safe working practices at all times.It was essential that, for our maintenance strategy to work, full cooperation was received from existing site staff. This involved gaining trust from both distributement and floor staff.The Novartis Ringaskiddy site, under the surface, functions as a group of almost autonomous areas. The production constructs, utilities, warehouse, armoured combat vehicle farm waste water areas all have designated management teams who all have in turn subtle but distinct differences in methods of operation.As emergency lighting is a utility that features across the site, the VEIS team had to find a way to adapt to the varying cultural practices in order to make our strategy work.Engaging in a deferent and sometimes almost deferential manner was the order of the day. Here are some of the bridges that had to be crossedMethod Statement evolutionThe method statement for emergency lighting mainten ance activities required look back and approval from both the HSE process safety manager and PB1 electrical engineer.The comic aspect to this is that neither of the other two site electrical engineers opted to review or approve the method statement despite organism presented with it. determine appurtenance A for cover page of Method Statement.Planning Meetings once again there was a variance here in that VEIS attended cyclical maintenance planning meetings in the PB2 production building only.This was to ensure that production and maintenance coordinators were aware of upcoming works. This obviously extended beyond emergency lighting to all VEIS related maintenance.It also helped ensure that the work permitters for the building had right notice as resources were tight in this area.For other areas on site, email notification was sufficient to alert NRL staff of pending activities. lymph node MeetingsAs part of our customer engagement strategy, we arranged separate periodical me etings with key staff from the PB1, PB2 and Technical Services areas.This provided a forum for all parties to express opinions on any issues or indeed the good password stories.KPI Score CardClient interaction was critical here. See scratch 13.0 for specific detail.ATEX areasIt was vital for VEIS to gain the confidence of the client in our ability to work safely and competently in the ATEX areas. As an embedded contractor, we were subject to more intense scrutiny than any sub-contractor that provided assists to the client. An example would be the purchase of a Fluke Ex multi-meter that we made. This came at a hail of 1000. All other electrical maintenance staff used the non-Ex ccc version.Asset RegisterIndividual emergency light fittings were not keep downed on the NRL asset register. The lowest aim the register went to was the of import political campaign Units. The Novartis engineers were tart to have a full schedule of emergency light fittings include in the asset registe r so it made sense for VEIS to supporter them. Aiding the NRL engineers with this task was not in the scope of the IFM contract but providing this service did much to solidify the relationship and further build trust. This was practically a mini project and involved the following activitiesCompiling the full constitute of fittings.Listing the fittings accurately by casing and by area.Redlining the lighting plans to hypothecate moved, removed or newly installed fittings.Confirming the ameliorate CTUs, Distribution Boards and MCBs.Liaising with the site electrical engineers to agree on a naming/tagging convention.Supplying redlined lighting plans to site drawing office for printing and uploading to the Novartis COMOS system.Site Manual (Play Book)A site manual or play book was developed which defined the scope of the VEIS IFM contract. This was a live document which evolved as the contract progressed and reflected any new services that were added to the remit of VEIS. The site ma nual was subject to periodic review by the Novartis IFM lead. High level maintenance strategies were also stored in in this book.In order to comply with rigorous onsite HSE policies, VEIS technical staff required training/certification with the followingATEX Awareness.Emergency Lighting fit Inspection.Confined Space Entry.Mobile Access Tower assembly.Current Good Manufacturing Practice.Fire Watch.Lock-out/Tag-out/ isolation.Mobile Elevated Work Platform operation. consent toting hot and rimy works.SAP CMMSUser level for FTs.Maintenance Planner level for Technical Team Lead.Working at Heights.Manual Handling.Safety Harness.As previously mentioned, the Emergency Lighting system had fallen into a state of disrepair on the Ringaskiddy site. With the arrival of VEIS onsite as the IFM provider, a new impetus was put on restoring the system to full operating order and maintaining it to a proper and obedient standard.In addition, it was quickly noticed by the VEIS team that list of eme rgency light fittings in the contract tender was not correct. There had been several additions and modifications to the system without proper records to reflect the changes.After a thorough appraisal, it was build that more than 100,000 would be required in parts purchasing to obligate out the necessary repairs. This would have to be actioned by VEIS as it was inwardly scope of the contract. addendum B lists the embodys of parts required to light upon a fully functioning emergency lighting system.All of the emergency light fittings on the NRL site are of the Self-Contained Emergency Luminaire variant.This type is defined as having all components such as the lamp, control social unit and battery either inside or not more than one metre from the fitting (Ventilux, n.d.).8.1 Various Types UsedFigures 2 and 3 attest both the most commonly used and most expensive to fill in fittings used at NRL.There are other types also such as Exit/Running Man and Twin Spot. Although these are evenly critical from a safety perspective, they came at a fraction of the cost to replace.It was decided because of the preferential pricing available for purchasing realize Stahl fittings that these would be used to replace defective CEAG units that were economically unrepairable.CEAG fittings were kept in service only when the repairs didnt extend beyond tube and battery replacement.Figure 2 Stahl Ex Emergency Light Fitting (Source Stahl)Figure 2 shows the types of Stahl light fittings used on the Novartis site (Stahl).Figure 3 CEAG Ex Emergency Light Fitting (Source Atex)Figure 3 shows the type of CEAG light fitting used on the Novartis site (Atex).8.2 Quantities of Fittings by Area ZoneTable 3Fitting TypeEx Zone 1Ex Zone 2Safe AreaMain Switch Room6Pump domiciliate15Tank Farm285728Solvent Recovery3369LVI1635PB 2563130PB 1530145PB 1A28578Waste Water5831Utilities55Technical Services95QA Labs88Warehouse93Canteen/HR/Administration125NIPBI Labs168Security Gate House7Sub Totals1455 2191064Grand Total2738Table 3 list the corrected amounts of light fittings by zone and by area.The more correct way to classify equipment suitable for use in Ex Zone 1 and Zone 2 areas is by true cat 2 and CAT 3 respectively. However it is normal in Industry to reference them by Ex Zone numbers only.Safe Area refers to type of light fittings used outside of the hazardous areas.8.3 Components ruin InformationThe one well-being of taking on a dilapidated system, from a maintenance perspective, is that you have the data to hand on the reasons why the assets have failed. Figure 4 displays a breakdown of these failure modes for the emergency light fittings on the Novartis site.This education was a key driver in deciding the amounts and types of spare parts to be held on site.Figure 4 Reasons for Light Fitting FailureFigure 4 illustrates failure data compiled on the NRL site.The Inspection and Maintenance activities evolved as the contract progressed on the Novartis site. The initial stages comprised of inspection and data gathering. This advanced to inspection, testing and repairs.9.1 Structure and Administration of premenstrual syndrome on CMMSNovartis utilises the SAP CMMS to deal out all of its maintenance activities. VEIS staff were prepare onsite in the use of this system. The Facilities Technicians were trained toUser level while the Technical Team Lead was trained to Planner level.As effective owners of the assets and systems that were in scope for the IFM contract, it was agreed that we would manage maintenance activities end-to-end.Here is a synopsis of how we ran this aspect of our operation for the emergency lighting systemPMs were built against the Asset IDs of the CTUs.The CMMS Created a PM01 Preventive Maintenance Work revision in advance of the Due betrothal based on the Call Horizon settings.The VEIS Planner Released the Work hostel in advance of the activity being carried out.One of the FTs printed the resultant origin Card.The FTs had a predetermined period of time from the Due Date to complete the activity so as not to exceed the Late Date.PMs that overshot the Late Date required Deviation Reports to be submitted. corrective activities were recorded utilize PM11 Deferred Maintenance or PM12 Immediate Maintenance Work Orders depending on the severity of the issue.Completed Job Cards and reports, where applicable, were uploaded to the CMMS and attached to the germane(predicate) Work Order before changing its status to Complete.See Appendix C for definitions of the terms used by the SAP CMMS.See Appendix D for an example of a Novartis Work Order raised on the SAP CMMS.9.2 Permitting for WorksThere was variance across the NRL site in how permits to work were processed. Again it was an example of how at a high level there was standard practice but the reality on the build was different.This was another area where VEIS had to adapt to the different actions and ensure both safety compliance and a timely manner for d elivering works. The time concern stems from extensive delays that could occur if one did not follow the specific permitting guidelines for a particular area.See Appendix F for a table displaying the differences per area in processing of permits to work on the NRL site.9.3 Inspection and TestingDaily TestThe following is the procedure employed for the fooling testTo complete the daily test of the emergency lighting system, one of the Facilities Technicians walks the site and guarantees the CTUs for presence of any faults.Permitting is not required for this activity.Any faults are recorded in the VEIS Emergency Lighting Logbook and repairs are put into the work queue.Visual Inspection of Emergency Lights Under the previous I.S. 3217 standard, all emergency light fittings had to be visually inspected weekly. This would have been near impossible for the VEIS team to deliver.The current standard stipulates that 25% of fittings are to be visually inspected weekly resulting in 100% bei ng checked in a four week period.The following is the procedure employed for the visual inspectionWhen conducting a visual inspection of the emergency lights in an area, the Facilities Technicians go away first contact the area supervisor to predicate them of the intention to stick out out an inspection.A permit and countersignature go forth then be requested if it is deemed necessary.Technicians allow foring use the access card victimize-in system or the sign-in logbook when entering the area if such systems are present.The Technicians pass on then walk the area and record their results in the VEIS Emergency Lighting Logbook.The area go out be odd in a clean and tidy state.They will swipe or sign out when sledding the area if such systems are present.If a permit was received then it will be returned and signed off.See Appendix E for take a chance Assessment table.Three Monthly Inspection (for a 3 mo self-contained system) The following is the procedure employed for a 3 monthly inspectionWhen conducting the Three Monthly Inspection of the emergency lights in an area, the Facilities Technicians will first contact the area supervisor to inform them of the intention to carry out an inspection.A permit and countersignature will then be requested.Signs will be placed at the entrances to the area to advise force-out that an inspection is taking place.Technicians will use the access swipe-in system or the sign-in logbook when entering the area if such systems are present.The emergency lighting Central Test Unit will then be activated, or in cases where a circuit is not on a CTU, the MCB will be switched off which will result in the emergency lighting going into fault mode.The Technicians will then walk the area and record their results in the VEIS Emergency Lighting Logbook.When complete the CTU will be reset and any MCBs that were switched off will be switched on.Faults that have been recorded will then be addressed.A suitable function will be used fo r the repairs.Where the step ladder is used, FTs should not exceed hip height to the top rung of the ladder.A safety harness will be cadaverous where required.A sustain will be used where required.Care is to be taken when using hand tools.A Hot Work Permit will be required to work near live capable parts such as using a meter to check for power.If replacing internal parts of the light or where a wire fault ineluctably to be rectified, then the circuit will be locked out at the lighting supply board with a MCB locking device and a padlock. VEIS staff will refer to Novartis SOP 000.926.0479 Isolation of electrically drive equipment.Before disconnecting any cable the FT moldiness always assure that the internal mains wiring is dead using a digital multi-meter.When work is complete then the area is to be left clean and tidy and all circuits should be powered up.They will swipe or sign out when leaving the area if such systems are present.The permit will be returned and signed off .See Appendix E for Risk Assessment table.Upon completion of the Three Monthly Inspection and testing, a report for inspection, testing and servicing as detailed in Annex C1 and Annex C7 of I.S. 32172013 shall be attached to the relevant SAP Work Order where it can be viewed/printed by the PU Manager and electrical engineer of (PB1,PB2,TS). As per 16.2.4.1 of I.S. 32172013. A copy of the report shall be placed in the VEIS Emergency Lighting Logbook.Annual Load Test (for a 3 hour self-contained system) The following is the procedure employed for the annual load testWhen conducting the Annual Load Test of the emergency lights in an area, the Facilities Technicians will first contact the area supervisor to inform them of the intention to carry out an inspection.A permit and countersignature will then be requested.Signs will be placed at the entrances to the area to advise military force that an inspection is taking place.Technicians will use the access swipe-in system or the sign-in l ogbook when entering the area if such systems are present.The emergency lighting Central Test Unit will then be activated, or in cases where a circuit is not on the CTU the MCB will be switched off, which will result in the emergency lighting going into fault mode.The Technicians will then walk the area and record their results in the VEIS Emergency Lighting Logbook.When complete the CTU will be reset and any MCBs that were switched off will be switched on.Faults that have been recorded will then be addressed.A suitable ladder will be used for the repairs.Where the step ladder is used, Technicians should not exceed hip height to the top rung of the ladder.A safety harness will be worn where required.A scaffold will be used where required.Care is to be taken when using hand tools.A Hot Work Permit will be required to work near live exposed parts such as using a meter to check for power.If replacing internal parts of the light or where a wiring fault needs to be rectified, then the ci rcuit will be locked out at the lighting supply board with a MCB locking device and a padlock. VEIS staff will refer to Novartis SOP 000.926.0479 Isolation of electrically driven equipment.Before disconnecting any cable the FT must always confirm that the internal mains wiring is dead using a digital multi-