Maintenance Program
The disciplined upkeep of every life-support-critical and husbandry-critical asset in the Station: a preventive maintenance schedule, a stocked critical-spares reserve, AquaLink-driven condition monitoring, and the uptime targets the building is held to. In an aquatic facility, maintenance is not housekeeping — it is the difference between a living system and a dead one.
Program Telemetry
Maintenance Strategy
Assets are maintained according to their consequence-of-failure, not their cost. A planted-tank CO₂ solenoid that fails costs a slow week of growth; a cold-water chiller that fails kills a whole system before the next shift change. The program therefore classifies every asset into one of three criticality tiers, each with a mandated maintenance philosophy and uptime target.
Predictive + 2N
Condition-monitored, redundant, tested on a short interval. Failure is a fish-kill or containment event. Target ≥ 99.99% availability.
Preventive
Scheduled PM on calendar/runtime. Failure degrades water quality or growth. Target ≥ 99.5% availability.
Planned + Run-to-Fail
Non-critical fabric and amenity. Repaired on a planned basis. Target ≥ 98% availability.
Preventive Maintenance Schedule
The master PM register. Intervals are enforced by the NEREID-Maint CMMS, which auto-generates work orders against runtime hours or the calendar, whichever falls first. Life-support-critical (C1) tasks cannot be deferred without Facilities Manager sign-off.
| System / Asset | Crit. | Interval | Task | Owner |
|---|---|---|---|---|
| Abyssal chillers (A/B) | C1 | Monthly (alt.) | Standby-train run, refrigerant charge, temp & trip verification | FAC-UTL |
| Abyssal cascade fans (A/B) | C1 | Monthly (alt.) | Standby-train run, pressure & interlock verification | FAC-BSZ |
| Life-support circulation pumps | C1 | Monthly | Standby auto-start test, flow & seal check, current draw | FAC-SYS |
| UPS & BESS (Essential Bus) | C1 | Monthly | Autonomy test, cell impedance, transfer test | FAC-UTL |
| Emergency genset | C1 | Weekly | On-load run, fuel polish, start-time log | FAC-UTL |
| O₂ / aeration backup | C1 | Monthly | Cylinder pressure, auto-switch test, regulator | FAC-SYS |
| Protein skimmers | C2 | Weekly | Cup clean, venturi clear, draw-rate set | FAC-SYS |
| UV / ozone units | C2 | Quarterly | Lamp-hour swap, quartz clean, ORP calibration | FAC-SYS |
| Drum / mechanical filters | C2 | Weekly | Screen clean, spray-bar, motor & level check | FAC-SYS |
| RO trains & membranes | C2 | Quarterly | Flux, conductivity, CIP, pre-filter swap | FAC-UTL |
| Heaters & temp controllers | C2 | Quarterly | Element test, controller cal, redundancy verify | FAC-SYS |
| Dosing skids & probes (pH/ORP/cond) | C2 | Weekly–Monthly | Probe cal, pump flow, tube replace | FAC-UTL |
| Footbaths & PPE gateways | C1 | Weekly | Charge, date, sensor-gate function test | FAC-BSZ |
| Switchgear / protection relays | C2 | Annual | Thermography, relay test, torque audit | FAC-UTL |
| Tank bunding & envelope seals | C2 | Annual | Bund integrity, leak-path, glazing/roof seal | FAC-STR |
| Dock decon & ballast assay kit | C2 | Monthly | Reagent stock, assay calibration, footbath charge | FAC-DCK |
| Gyre Station LSS (remote) | C1 | Per resupply | NEREID self-test + tender inspection, solar/wave & battery | FAC-SYS |
| Lifts, doors, quarters fabric | C3 | Annual | Statutory inspection, planned refurbishment | FAC-STR |
Critical-Spares Reserve
The critical-spares reserve holds long-lead and single-point-of-failure components for C1/C2 assets so a life-support repair is never gated on procurement. A chiller cannot wait six weeks for a compressor while a system warms. Stock is reordered automatically by the CMMS at the reorder point.
| Spare | For Asset | Qty Held | Reorder Pt. | Lead Time |
|---|---|---|---|---|
| Chiller compressor + controller | Abyssal / Reef chill | 2 | 1 | 6 wk |
| Cascade fan motor + VFD | Abyssal cascade | 2 | 1 | 8 wk |
| Life-support pump (each frame size) | System circulation | 4 | 2 | 4 wk |
| UV lamp + quartz sleeve sets | UV sterilizers | 30 | 12 | 2 wk |
| Ozone generator cell | Reef / Quarantine ozone | 2 | 1 | 5 wk |
| RO membrane elements | RO trains | 12 | 6 | 5 wk |
| O₂ cylinders (charged) | Aeration backup | 8 | 3 | 1 wk |
| Titanium heater + controller | Tropical systems | 16 | 6 | 2 wk |
| pH / ORP / cond. probe kit | Dosing skids | 24 | 10 | 2 wk |
| UPS battery string | Essential Bus | 1 string | 1 string | 10 wk |
| Genset injector / starter set | Emergency genset | 2 sets | 1 set | 6 wk |
AquaLink Condition Monitoring
The program is not purely calendar-driven. The AquaLink sensor mesh instruments every system and feeds NEREID, which turns drift into a work order before a failure becomes a fish-kill. A pump bearing that is heating, a chiller that is taking longer to pull down, a skimmer whose draw is fading, a UV lamp past its dose hours — each generates a condition-based work order that pre-empts the calendar PM.
- Vibration & current: pumps and fans trend motor current and vibration; a rising signature pages FAC-SYS before seizure.
- Thermal: chiller pull-down time and approach temperature are trended; degradation flags a compressor service early.
- Water-quality drift: AquaLink correlates a slow O₂, ORP, or clarity decline to the responsible LSS asset, not just the symptom.
- Runtime & dose hours: UV lamps, ozone cells, and RO membranes are tracked on usage, not just date.
- Predict-to-prevent: condition work orders are prioritized above calendar PMs on the same asset — the mesh decides the interval, the calendar is the floor.
Work-Order / CMMS Process
All maintenance flows through the NEREID-Maint CMMS — there is no undocumented repair on a graded asset. Work orders originate from three sources: auto-generated PMs, condition-monitoring alarms from the AquaLink mesh, and manual requests. Every order carries an asset ID, criticality, permit requirements, and a closure record.
- 1 · Raise: WO created (auto-PM, alarm-triggered, or manual) with asset tag, criticality, and symptom.
- 2 · Triage: CMMS assigns priority from criticality × urgency; C1 alarms page the on-call lead immediately.
- 3 · Permit: work inside Quarantine requires a Permit-to-Work; Restricted (Abyssal) work requires Director authorization and a standby train.
- 4 · Plan: spares reserved, isolations identified, lock-out/tag-out and impact on redundancy assessed.
- 5 · Execute: work performed by the owning function; safety-critical steps witnessed by a second person.
- 6 · Verify: function test against acceptance criteria (e.g. chiller re-establishes setpoint, cascade re-establishes −55 Pa).
- 7 · Close: labor, parts, downtime, and root cause recorded; reliability data feeds the next PM interval review.
Uptime Targets — Life-Support-Critical Systems
| System | Availability Target | Max Annual Downtime | Redundancy | Trailing 12 mo |
|---|---|---|---|---|
| Abyssal chill plant | ≥ 99.99% | ≤ 53 min | 2N chill trains | 99.996% |
| Abyssal pressure cascade | ≥ 99.99% | ≤ 53 min | 2N fan trains | 99.997% |
| Essential Bus power | ≥ 99.99% | ≤ 53 min | UPS + N+1 genset + BESS | 99.994% |
| System circulation & O₂ | ≥ 99.95% | ≤ 4.4 h | Dual pump + O₂ backup | 99.97% |
| Filtration & skimming | ≥ 99.5% | ≤ 1.8 d | Dual on large systems | 99.8% |
| RO & water make-up | ≥ 99.5% | ≤ 1.8 d | N+1 train + 72 h reservoir | 99.9% |
| Quarantine isolated LSS | ≥ 99.9% | ≤ 8.8 h | Per-lot redundancy | 99.6% |