Facilities Asset Management Program




Wastewater Advisory
    Committee
     March 2009
Today’s Agenda


• Change in organization
• Capital Programs 09-13
• Update on FAMP Program
• Condition Monitoring update
...
Components of the Deer Island FY09 CEB
                      Other
                       3%




                         ...
Deer Island Wastewater Treatment Plant
•   Result of $3.8 Billion
    Dollar Construction
    Project

•   2nd Largest Was...
Operations Division      – Deer Island Wastewater Treatment Plant

                                                  OFFIC...
DEER ISLAND – OFFICE OF THE DIRECTOR
                                                             FY 09


                ...
DEER ISLAND ENGINEERING SERVICES
                            FY09



                         Richard Adams
              ...
DEER ISLAND MAINTENANCE
           DEPUTY DIRECTOR’S OFFICE
                     FY09


                        Stephen C ...
Today’s Agenda


• Change in organization
• Capital Programs 09-13
• Update on FAMP Program
• Condition Monitoring update
...
Capital Project Spending
•   FY 09 through FY12 Spending :$ 240M
•   FY 09 Anticipated Awards $86.5M
•   FY 10 Anticipated...
Capital Projects
•   FY09: 12 projects
•   FY10: 22 projects
•   FY11: 14 projects
•   FY12: 12 projects
       •Residuals...
CEB Projects
• Responsible for the development of bid
  documents
• Responsible for Project management
• Service contract ...
PRIMARY AND SECONDARY
CLARIFIER REHABILITATION
        PROJECT
Interior of Primary Clarifier-Battery A
Longitudinal Chain                                             Longitudinal Chain
    Tensioner
                          ...
Clarifier Chain Failures
(Top) Side View of failed Clarifier Chain in service 11 years (type 403)
(Middle and Bottom) Side and Top View of New Sect...
Significant Corrosion on Primary Chain (Typical)
RESIDUALS PIPE
REPLACEMENT PROJECT
Residual Gallery




    (Left) Residuals Pipe Gallery
    (Right) Section of Pipe Removed for Inspection
10” Glass Lined Reducer
DIGESTED SLUDGE PUMP
      PROJECT
NMPS VFD/MOTOR
 REPLACEMENT
H1S/H1R PIPELINE
    FAILURES
H1S/H1R Piping Failure
WIND TURBINES
CSB Demo
Diesel Removal
FUEL OIL LINE
REPLACEMENT
ELECTRICAL UPGRADE 3
Back Pressure Turbine Generator
Today’s Agenda


• Change in organization
• Capital Programs 09-13
• Update on FAMP Program
• Condition Monitoring update
...
Asset Management Program

• Drivers
  – Business Strategy #21: develop and
    implement an agency-wide multi-year
    mai...
Reliability Centered Maintenance (RCM)

           • RCM is a structured process where
             the system experts (op...
Reliability Centered Maintenance
              (RCM)
      • RCM is a structured process where
        the system experts ...
RCM - Approach


                                                                                                      Rev...
RCM as of 3-1-09
• DITP status
  – 83 RCM analyses completed
  – 72 currently implemented

• DITP results
  – Overall 24% ...
Maximo Highlights
•   72,710 Pieces of equipment in Maximo
•   99.1% Equipment availability
•   32,435 Work Orders per yea...
Software Utilization
• Maximo 5.2
• Lawson/Maximo interface
• Increase Functionality
   – Link documents
   – Data-base ro...
Training
– Alignment Training

– Maximo Training

– RCM Training

– Arc flash training

– Vendor Presentations

– New Proc...
Procedures
• Maximo desk guide (Porthole of Knowledge)
  – Enter a Work Request
  – Work Order procedure
  – PM procedure
...
Benchmarking
• Site Visits and Meetings conducted
with Fortune 500 companies and
others to expand MWRA program
  – Dofasco...
MWRA Shares Best Practices

– City of Detroit, Water & Sewerage

– King County, Seattle, Wastewater Division

– Gillette W...
Today’s Agenda


• Change in organization
• Capital Programs 09-13
• Update on FAMP Program
• Condition Monitoring update
...
Condition Monitoring


• Non-intrusive maintenance techniques

• Monitor health of high cost, critical assets

• Alert sta...
Condition Monitoring at DITP

• Lubrication / Oil Analysis

• Vibration

• Temperature

• Thermography

• Ultrasonic
Lube oil benefits
• Recommendations
  – No change required
  – Filter oil
  – Change oil
• Results
  – OEM oil changes wou...
Boiler Force Draft Fan Bearing

              Vibration analysis on GB:MS.F-202
              fan had increased vibration ...
Thermography

•Steam Trap testing using Infrared Imaging
•Ensure steam traps are operating as designed
•High heat or yello...
Ultrasonic Program
• Thickness Ultrasonic
  – Carbon Absorbers
  – Heat exchangers
• Acoustic Ultrasonic
  – Mixer Aerator...
Today’s Agenda


• Change in organization
• Capital Programs 09-13
• Update on FAMP Program
• Condition Monitoring update
...
Components of FY09 Maintenance CEB



                         Electrical Services
                                       ...
Maintenance at DITP
• 118 staff (Technicians & Supervisor’s)
• 32,435 total work orders per year
• Maintenance Craft Hour ...
Maintenance Planning
• Maintenance Priority List
   – Meet weekly with operations/Maintenance/Engineering
   – Discuss hig...
Maintenance Staffing
200
180      152
160             135
140                    120   118
                               ...
% of Work Orders Completed




       0
           10
                20
                     30
                         ...
% of PdM Work Orders




       0%
            2%
                 4%
                      6%
                           ...
Operations Light Maintenance PMs

                      20%
                      18%
% of Total PM Hours




            ...
Maintenance Metrics

Benchmark                                 Industry Goal                  DITP (2009)
Maint. Spending/...
Today’s Agenda


• Change in organization
• Capital Programs 09-13
• Update on FAMP Program
• Condition Monitoring update
...
Service contracts
• Maintenance contracts
  –   Cryogenics                     3yr   1.5M
  –   Centrifuge                ...
Service Contracts
• Facility contracts
  – Janitorial         3yr   1.7M
  – Landscape          3yr   305K
  – Security   ...
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
Facilities Asset Management Program
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Facilities Asset Management Program

  1. 1. Facilities Asset Management Program Wastewater Advisory Committee March 2009
  2. 2. Today’s Agenda • Change in organization • Capital Programs 09-13 • Update on FAMP Program • Condition Monitoring update • Maintenance Metrics • Service contracts
  3. 3. Components of the Deer Island FY09 CEB Other 3% Wages & Salaries 32% Maintenance 28% Water 2% Overtime 2% Diesel Fuel 1% Chemicals 6% Electricity 26% Deer Island’s Amended Budget $52,222,816
  4. 4. Deer Island Wastewater Treatment Plant • Result of $3.8 Billion Dollar Construction Project • 2nd Largest Wastewater Treatment Plant in the United States • Built on 120 Acres • Treatment Capacity: – Maximum • 1.27 Billion Gal/Day – Average Daily Flow: • 365 Million Gal/Day
  5. 5. Operations Division – Deer Island Wastewater Treatment Plant OFFICE OF THE DIRECTOR John P . Vetere 2915001 (N U /16 ) D irector D eer Island Wastewater Treatm ent Plant John R iccio Vacant Michael Walsh D an O’B rien Gerard Gallinaro 2910001 (N U /14 ) 2915010 (N U /15 ) 2915011 (N U /15 ) 2915012 (N U /15 ) 2915013 (N U /15 ) Superintendent D eputy D irector D eputy D irector Manager D eputy D irector C linton WW Treat . Pt . Operations O& M Support C apital Program Maintenance 7 Positions 69 Positions 20 Positions 148 Positions 11 Positions Wastewater Wastewater Safety Trade Labor C apital Treatm ent Treatm ent Im provem ent Security Planning Landfill Pellet Plant TIC C enter Operation A dm in C ondition Process control Monitoring Therm al Plant Eng
  6. 6. DEER ISLAND – OFFICE OF THE DIRECTOR FY 09 John P . Vetere 2915001 (NU/ 16) Director Deer Island Wastewater Treatment Plant John Riccio Dan O’Brien Michael Walsh Richard Adams Stephen Cullen Kristen Pateneaude 2910001 (NU/ 14) 2915010 (NU/ 15) 2915011 (NU/ 15) 2915012 (NU/ 15) 2915013 (NU/ 15) 2910015 (9/29) Superintendent Deputy Director Deputy Director Manager Deputy Director Program Manager Clinton WW Treat . Pt . Operations O&M Support Engineering Services Maintenance Energy Management 7 Positions 66 Positions 19 Positions 18 Positions 136 Positions
  7. 7. DEER ISLAND ENGINEERING SERVICES FY09 Richard Adams Manager , Engineering Services Capital Planning Engineering 2 Positions 10 Positions TIC Center 6 Positions Long Term Planning Plant Engineering Service Contract Document control Budget Construction Resident Engineering
  8. 8. DEER ISLAND MAINTENANCE DEPUTY DIRECTOR’S OFFICE FY09 Stephen C . C ullen D eputy D irector , Maintenance D avid Shea Teddy R egan 2988004 2988005 Maintenance , Manager A ssets Manager 13 Positions 121 Positions Planners /Scheduler Trade labor C ondition Monitoring Pumping Liquid Train R esiduals Facilities C ore
  9. 9. Today’s Agenda • Change in organization • Capital Programs 09-13 • Update on FAMP Program • Condition Monitoring update • Maintenance Metrics • Service contracts
  10. 10. Capital Project Spending • FY 09 through FY12 Spending :$ 240M • FY 09 Anticipated Awards $86.5M • FY 10 Anticipated Awards $73.0M • FY 11 Anticipated Awards $27.6M • FY 12 Anticipated Awards $52.9M
  11. 11. Capital Projects • FY09: 12 projects • FY10: 22 projects • FY11: 14 projects • FY12: 12 projects •Residuals • Equipment Assessment • Sludge to energy technology • Contract end date 2015
  12. 12. CEB Projects • Responsible for the development of bid documents • Responsible for Project management • Service contract examples: Elect Maint., Boiler Maint, CTG Maint, STG Maint, Landscaping, Roofing, Coating, etc.) • 23 Contracts Totaling $15.8M
  13. 13. PRIMARY AND SECONDARY CLARIFIER REHABILITATION PROJECT
  14. 14. Interior of Primary Clarifier-Battery A
  15. 15. Longitudinal Chain Longitudinal Chain Tensioner Tensioner Longitudinal Shaft and Sprockets Longitudinal Chain Interior of Primary Clarifier-Battery B
  16. 16. Clarifier Chain Failures
  17. 17. (Top) Side View of failed Clarifier Chain in service 11 years (type 403) (Middle and Bottom) Side and Top View of New Section of Clarifier Chain (Type 403)
  18. 18. Significant Corrosion on Primary Chain (Typical)
  19. 19. RESIDUALS PIPE REPLACEMENT PROJECT
  20. 20. Residual Gallery (Left) Residuals Pipe Gallery (Right) Section of Pipe Removed for Inspection
  21. 21. 10” Glass Lined Reducer
  22. 22. DIGESTED SLUDGE PUMP PROJECT
  23. 23. NMPS VFD/MOTOR REPLACEMENT
  24. 24. H1S/H1R PIPELINE FAILURES
  25. 25. H1S/H1R Piping Failure
  26. 26. WIND TURBINES
  27. 27. CSB Demo
  28. 28. Diesel Removal
  29. 29. FUEL OIL LINE REPLACEMENT
  30. 30. ELECTRICAL UPGRADE 3
  31. 31. Back Pressure Turbine Generator
  32. 32. Today’s Agenda • Change in organization • Capital Programs 09-13 • Update on FAMP Program • Condition Monitoring update • Maintenance Metrics • Service contracts
  33. 33. Asset Management Program • Drivers – Business Strategy #21: develop and implement an agency-wide multi-year maintenance plan • Goals – Protect Ratepayer Investment – Prolong Asset Life – Preserve the Environment
  34. 34. Reliability Centered Maintenance (RCM) • RCM is a structured process where the system experts (operations and maintenance staff) jointly analyze system components and recommend the most appropriate maintenance requirements (including tasks, frequencies and trades) of physical assets as they are operated • Concept developed over a period of thirty years by the aviation industry
  35. 35. Reliability Centered Maintenance (RCM) • RCM is a structured process where the system experts (operations and maintenance staff) jointly analyze system components and recommend the most appropriate maintenance requirements (including tasks, frequencies and trades) of physical assets as they are operated • Concept developed over a period of thirty years by the aviation industry
  36. 36. RCM - Approach Review Audit Analysis Meetings Comments Establish Prepare Identify Identify Notify Management Meeting Operating Implement Systems Group Members Audit Schedule Context Gather data Must be 3- • PM Tasks Day RCM Set analysis Trained boundaries • PdM Tasks Analysis Meetings • SOPs • Design reviews • Review operating context • Training • Define functions • Define functional failures • Asset Manager • Define failure modes (causes) • Describe failure effects • RCM Facilitator • Discuss failure consequences • Determine tasks/actions to prevent failures
  37. 37. RCM as of 3-1-09 • DITP status – 83 RCM analyses completed – 72 currently implemented • DITP results – Overall 24% reduction in PM cost • DITP future – 110 total systems to complete – Annual reviews to stay current
  38. 38. Maximo Highlights • 72,710 Pieces of equipment in Maximo • 99.1% Equipment availability • 32,435 Work Orders per year • 1800 Preventive Maintenance/month • 100% Preventive Maintenance completed • 12 % Predictive Maintenance • < 1% Emergency Maintenance
  39. 39. Software Utilization • Maximo 5.2 • Lawson/Maximo interface • Increase Functionality – Link documents – Data-base roll-up – Performance reporting – Required fields – PICS Maximo Interface – Enhanced Queries
  40. 40. Training – Alignment Training – Maximo Training – RCM Training – Arc flash training – Vendor Presentations – New Procedures
  41. 41. Procedures • Maximo desk guide (Porthole of Knowledge) – Enter a Work Request – Work Order procedure – PM procedure – Equipment change procedure – QA/QC procedure
  42. 42. Benchmarking • Site Visits and Meetings conducted with Fortune 500 companies and others to expand MWRA program – Dofasco Steel, Canada – Broward County, Florida – Coors Brewing and Ball Industries – Society for Maintenance & Reliability Professionals (www.SMRP.org)
  43. 43. MWRA Shares Best Practices – City of Detroit, Water & Sewerage – King County, Seattle, Wastewater Division – Gillette Worldwide – MIT – Boston Public Library – Mass General
  44. 44. Today’s Agenda • Change in organization • Capital Programs 09-13 • Update on FAMP Program • Condition Monitoring update • Maintenance Metrics • Service contracts
  45. 45. Condition Monitoring • Non-intrusive maintenance techniques • Monitor health of high cost, critical assets • Alert staff well in advance of pending failure
  46. 46. Condition Monitoring at DITP • Lubrication / Oil Analysis • Vibration • Temperature • Thermography • Ultrasonic
  47. 47. Lube oil benefits • Recommendations – No change required – Filter oil – Change oil • Results – OEM oil changes would cost $83,514.00 – Cost - Sample/filtering/oil change $26,372 – Cost avoidance $57,142
  48. 48. Boiler Force Draft Fan Bearing Vibration analysis on GB:MS.F-202 fan had increased vibration levels. The vibration analysis detected a loose torque bolt avoiding a unexpected shut down. Green – Original data – grease and change oil Red – high range vibration – bearing issue Blue – Vibration after bearing repair – excellent vibration
  49. 49. Thermography •Steam Trap testing using Infrared Imaging •Ensure steam traps are operating as designed •High heat or yellow would indicate a problem Steam Traps Infrared Image
  50. 50. Ultrasonic Program • Thickness Ultrasonic – Carbon Absorbers – Heat exchangers • Acoustic Ultrasonic – Mixer Aerators – Centrifuge – RWW Motors
  51. 51. Today’s Agenda • Change in organization • Capital Programs 09-13 • Update on FAMP Program • Condition Monitoring update • Maintenance Metrics • Service contracts
  52. 52. Components of FY09 Maintenance CEB Electrical Services Other Materials & Services 9% 2% P&M Materials Special Equipment Services 21% 3% HVAC Materials 4% P&M Services Electrical Materials 33% 4% C&G Services 24% Deer Island’s Maintenance Amended Budget $14,559,850
  53. 53. Maintenance at DITP • 118 staff (Technicians & Supervisor’s) • 32,435 total work orders per year • Maintenance Craft Hour Distribution – 24% Preventive/Predictive Maintenance – 57% Corrective Maintenance – 17% Projects – 1% Emergency – 1% Other (Warranty, Event)
  54. 54. Maintenance Planning • Maintenance Priority List – Meet weekly with operations/Maintenance/Engineering – Discuss highest priority work – Maintenance uses to create area Daily Dispatch • Daily Dispatch record – Plan for tomorrow and schedule for the day – Schedule eights hour of work for all technicians – Includes WO#, Description, Location, # of hours – Priority work/PM/Projects – Management tracks productivity
  55. 55. Maintenance Staffing 200 180 152 160 135 140 120 118 118 120 100 80 60 40 20 0 FY99 FY01 FY04 FY06 FY08 Staff 152 135 120 118 118
  56. 56. % of Work Orders Completed 0 10 20 30 40 50 60 70 80 90 100 FY99 FY00 FY01 FY02 Industry Benchmark FY03 FY04 Preventive Maintenance FY05 FY06 FY07 FY08
  57. 57. % of PdM Work Orders 0% 2% 4% 6% 8% 10% 12% FY99 14% FY00 FY01 FY02 FY08 DITP Target FY03 FY04 Predictive Maintenance FY05 FY06 FY07 FY08
  58. 58. Operations Light Maintenance PMs 20% 18% % of Total PM Hours 16% 14% 12% 10% Industry Benchmark 8% 6% 4% 2% 0% FY99 FY00 FY01 FY02 FY03 FY04 FY05 FY06 FY07 FY08
  59. 59. Maintenance Metrics Benchmark Industry Goal DITP (2009) Maint. Spending/RAV 1.0-1.5% 1.26% Availability 97% 99.1 % Emergency Maintenance < 5% < 1% Overtime <5% 4% Operations Light Maint. 10-15% 17% Backlog 3-6 weeks 7.9 weeks Benchmark data was taken from industry data including Society of Maintenance & Reliability Professionals, International Benchmarking Clearinghouse, Maintenance Technology Magazine, Maintenance Handbooks, and various technical papers from Fortune 500 companies and Maintenance Consultants.
  60. 60. Today’s Agenda • Change in organization • Capital Programs 09-13 • Update on FAMP Program • Condition Monitoring update • Maintenance Metrics • Service contracts
  61. 61. Service contracts • Maintenance contracts – Cryogenics 3yr 1.5M – Centrifuge 3yr 800K – Combustion Turbine Generator 3yr 655K – Steam Turbine generator 3yr 924K – Boiler 3yr 3.1M – M/V Electrical Testing 3yr 1.7M
  62. 62. Service Contracts • Facility contracts – Janitorial 3yr 1.7M – Landscape 3yr 305K – Security 3yr 3M – Overhead doors 2yr 72K – Trash removal 2yr 251K
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