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HomeMy WebLinkAbout04.a. Receive update on the Asset Management Program Page 1 of 11 Item 4.a. CENTRAL SAN March 17, 2020 TO: ENGINEERING AND OPERATIONS COMMITTEE FROM: NITIN GOEL, SENIOR ENGINEER REVIEWED BY: DANEA GEMMELL, PLANNING AND DEVELOPMENT SERVICES DIVISION MANAGER JEAN-MARC PETIT, DIRECTOR OF ENGINEERING AND TECHNICAL SERVICES ROGER S. BAILEY, GENERAL MANAGER SUBJECT: RECEIVE UPDATE ON THE ASSET MANAGEMENT PROGRAM Please see the attached presentation. Strategic Plan Tie-In GOAL FIVE: Maintain a Reliable Infrastructure Strategy 1 - Manage assets optimally throughout their lifecycle ATTACHMENTS: 1. Presentation March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 20 of 32 Page 2 of 11 �• res „+ ASSET MANAGEMENT ACCOMPLISHMENTS Nitin Goel Senior Engineer Special Projects and Asset Management Group Engineering and Operations Committee Meeting �- .,a March 17, 2020 AGENDA Board Policy for Asset Management • Asset Management Program .�_. --%• ° Background and Status -� --= �.�o-==.�,•�--- • Asset Management Tools PURPOSE The purpose of this Board Policy is to recognize that the District has invested significant resources in its assets,and • Steam and Aeration Blower aims to optimize the lifecycle of these assets to deliver high quality and reliable services in a sustainable manner for customers with an acceptable level of risk. Systems Renovations, District - - Project 7349 (Steam Project) C March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 21 of 32 1 Page 3 of 11 CENTRAL SAN HAS A GEOGRAPHIC INFORMATION SYSTEM (GIS) CENTRIC ASSET MANAGEMENT ECOSYSTEM rf?Works KM InfoMastW Cityworks DYNAC° H draulic Ca Risk Model Asset Maintenance PV'anl Canliul y Capacity System(SCADA) Model Priorkixed Capital Plan Management /1 11 I I eesnArcGls �' Enterprise ® Dati Automation EIs nterprlse Geodatabases and Map Services — Resource Planning CCN Inspection/ Geocortex' canditi.n assessment ® aapbe Web Mapping Applications ColdFuslon Land Vse Spare Parts plG-SMART Management Tool Mana em t t DSA Locating K� g en F Data flow • 1°n F— Web hyperlinks mma°an°n ene ' 3 STATUS OF ASSET MANAGEMENT IMPLEMENTATION PLAN ELEMENTS IDENTIFIED FOR CENTRAL SAN IN APRIL 2015 1 Asset Management Organization,Policies,and Key Strategies 2 Asset Register 3 Plant Maintenance Strategy f 4 Business Process Mapping J 5 Knowledge Management Strategy In Progress 6 Condition Assessments In Progress 7 Business Risk Exposure In Progress 8 Failure-Based Maintenance Strategies In Progress 9 Asset Valuations In Progress 10 Program and Project Management Standards In Progress 11 Asset Commissioning and Handover Y 12 Strategic Forecasting In Progress 13 Capital Improvement Program Business Case Evaluations V 14 Update Asset Management Plan In Progress ' A CFNTPAISAN March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 22 of 32 2 Page 4 of 11 ASSET MANAGEMENT TOOLS DEVELOPED IN 2019 TO OPTIMIZE LIFECYCLE OF ASSETS & DELIVER HIGH QUALITY & RELIABLE SERVICES WOULD NOT BE POSSIBLE WITHOUT THE COLLABORATION & INNOVATION FROM MAINTENANCE, CSO, ENGINEERING, & OPERATIONS ConditionIlk" Engineering 1ReliReport ability Engineering 2 Ilk, Pipeline Cleaning IF Collection System kk Schedules Optimization O,_ . ASSET Operations MANAGEMENT 3Data Optim nt S Streamline workflow Maintenance 16 W391TY'Vow-M2 EXAMPLE 1 : BACKGROUND FOR CONDITION ASSESSMENT - RELIABILITY ENGINEERING REPORT • In Central San Asset Registry, there Treatment Plant Asset Infnrinatjnn s�wiuy e°r�m°ITre.m.°g.M n�.m o°q1 are 5,600+ assets in Treatment Plant and Pumping Stations ° • These assets are organized into 70+ asset classes w. w�°W•°••° °�nm °°°° • CMMS Cityworks®does not have a functionality to see which assets have preventative maintenance W7t (PM)work order cycles �. ro° ..° .�. .� . G�. ..,. .� . °. Also, did not have a way to view all assets within a specific process 16 March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 23 of 32 3 Page 5 of 11 EXAMPLE 1 : TOOL FOR CONDITION ASSESSMENT - RELIABILITY ENGINEERING REPORT • To access the tool,go to the Treatment Plant Portal °°�•°••a°^ • Tool classifies assets in a process hierarchy to make searching,querying,and analyzing assets faster µ•••• • Ability to see spare assets and spare parts • Ability to filter and sort by process,asset class • Perform Risk Analysis by viewing • Consequence of Failure(COF) y" • Probability of Failure(POF) • Business Risk Exposure(BRE)ratings • The COF, POF,and BRE ratings will be continually updated based on asset-based condition assessments „ F • Ability to see which assets have preventative and predictive work order cycles ° • Ability to view which assets have predictive maintenance " " """ © C a 0 (e.g.vibration analysis and temperature analysis)work "°°°°° """ "' A © 0 D 0 order cycles and which assets have a maintenance program assessment(e.g. root cause analysis and 0 a 0 n O Reliability Centered Maintenance(RCM)) ' 7 EXAMPLE 1 : CONDITION ASSESSMENT - RELIABILITY ENGINEERING REPORT BENEFITS Asset Maintenance Information a. • Tool provides insight into the work being done AiaremVMmid:5Nf1.0MW!MIN lm M p by Central San's Reliability Engineering group to maximize the useful life of Treatment Plant -•�•^�•�•^"- �•- �• --�•-- «--•••�--� ••--•• and Pumping Station assets - • It can also be used to filter assets by process/sub process/system, asset class, "`.;: �• ,pip �� _ _�asm���.n. " "' availability of spare assets, availability of • ",.,n .. � ,_ """'"ss" '" _ " spare parts, preventive and/or predictive maintenance programs, and whether a H.,�„o .• __�_,w, ”a__sa_. o _, reliability analysis was performed ,.a """ "" """"""� """" "�°"" °"'" • Reduces maintenance cost .,.W-,.nn ,ems ",. �.._..�m,�. �,.,....,��a..._.,,,,,..• .. „ •,","•••�� 0,, • Improves employee safety • Extends remaining useful of the assets life 1 8 CFNTPAI SAN March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 24 of 32 4 Page 6 of 11 EXAMPLE 2: BACKGROUND FOR OPTIMIZING PIPELINE CLEANING SCHEDULE • CSO had over 20,000 cleaning work orders in 2018 1» • Many PM cleaning schedules were established when Central San used index cards to track cleanings 0 O • Cleaning schedule and location were unevenly distributed • For example: some months have up to 50% more cleaning footage scheduled than other l l months • Cleaning locations were not optimized by location and were not synched on frequency cleaning intervals W391TY'Vow-M2 1 9 EXAMPLE 2: TOOL TO GROUP PIPELINE CLEANING SCHEDULES BY LOCATION • The web GIS application enables CSO staff to view cleaning based on schedule frequency intervals and by location • Central San staff can schedule pipes "k`TA based on connected pipes on the same frequency schedule in the same area ®_3•�• J ,� ^ . • Ability to click on each pipe to view ®_ ; custom Asset Maintenance Information Report to get insight on how much cleaning is scheduled ®- � • 1 1 +u- each month ®- _. Asset Management Application • Ability to project out seven years e San staff to schedule pipes for cleaning based - on location crew time _. • Ability for staff to schedule mains(or to optimize groups of mains)to manage distribution of schedules by month CFNTPAISAN March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 25 of 32 5 Page 7 of 11 EXAMPLE 2: OPTIMIZATION PIPELINE CLEANING SCHEDULE BENEFITS • The CSO Web Map and Analysis Asset Maintenance Information [imory Ma-,Pre,cn1 I1 WIM-PrgJwm FwtNcs tools optimize the process of how Central San cleans its pipes using geospatial location information • Previous method of using Excel , spreadsheets and forms for - ,...., organizing and scheduling cleaning was a time-consuming effort • These optimizations mean more effective utilization of staff time, *° increased productivity, increased ' ability to absorb unplanned work, . •,.•., reduced vehicle wear-and-tear, reduced costs, and reduced impact on the public CFNTPAISAN EXAMPLE 3: PRESSURE RELIEF AND WYE DEMOTION PROCESS BACKGROUND • For our asset registry on sewer gravity main, the -- pipes are segmented by pressure reliefs and wyes as defining structures "F lFXMIOW ••••••�••• w. • Example: Pipe Segment J[3R0%E ' C6 between M20 and M18 ef+fn[OOP • There is Pressure Relief (PR) 19 in-between H[OOv ' s Previously, crew would °•^� -- ---- enter at M20 to clean or �� inspect M20 to PR19 •UNIW Then travel to M18 and enter at M18 to clean or inspect M18 to PR19 March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 26 of 32 6 Page 8 of 11 EXAMPLE 3: PRESSURE RELIEF AND WYE DEMOTION PROCESS PROCEDURE BEFORE: M20/PR19 PR19/M18 M20 PR19 M18 AFTER: M20/M 18 I M20 PR19 M18 13 WUHTITIM M, EXAMPLE 3: PRESSURE RELIEF AND WYE DEMOTION PROCESS BENEFITS • Combined over 2,000 pressure relief pipe °so; ,;;"a°;°•'"`°'"�"°" segments and their related work orders u •. °•, • Combined over 500 wye-related pipe ��• - w �- segments and related work orders ==. E. • Enhanced GIS data structure through the - pressure relief demotion project - •°u- --- „� - • Streamlined the cleaning and inspection process - ••w •-- _ -- • Resulting in the elimination of unintended w _ w- duplication of cleaning efforts •m• — - ■ - • Decreasing the numbers of work order cleaning crews needed to open ' 14 CFNTPAISAN March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 27 of 32 7 Page 9 of 11 STEAM PROJECT SCOPE, MAJOR WORKSHOPS, & BUDGET Confirm r Detailed . . 10 Date 01.14.20) tember , . � 1 —CMEMMI'll o r nfirm Project .. Lifecycle Costs for Alternatives Workshop Month- September 2020) ' 15 STEAM PROJECT OVERALL OBJECTIVES As apart of the Steam Project, condition STEAMPR03ECTPHASEI-A55ESSINGTHECONOITIONOF p 1 THE STEAM&AE RATI ON SYST EM. �. assessment, performance testing, business case evaluations, and pre-design will be performed to address the following objectives: '- • Optimizing the life cycle cost of steam and secondary process asset • Employee safety '- •-•-- ----w---- • Reliability of operation »„ = - ;�- • • Meeting current and future demands =' �`= "—" • • Reliability of permit compliance • Reduction of operation and maintenance cost ' 16 March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 28 of 32 8 DEFINED CONDITION Condition score can be identified to each Level of Condition Assessments. Wevel4— Forensic Non- Testing Level 3— Destructive Performance Testing A4 Visual Field Inspection Lev Expected Life a �OD CENTRALSAN sSid • Define assets Visual condition Maintenance history • Request&review assessment of the asset review asset information Recording available data Condition assessment • Establish criticality &photographs field work scoring system Noting observations Staff interviews • Develop condition Collection of samples Estimate remaining assessment plans (if applicable) service life Step 3:Engineering Step 1:Planning and Step 2: Inspection Analysis Initial Evaluation (3 Steps to Estimate Service Life) CFNTRAI SAN • Page 11 of 11 STEAM SYSTEM ASSETS THAT ARE EVALUATED PART OF STEAM PROJECT Solids . . Srrrm C—brifuge System Hot Water Heater Exchanger Pumping and Sanpltng 9rytern' Copolymer BlowerBuilding hoilerfeedwate,and {ta Boilers) Electric 6lowdown mpling L I F ed S t Condenser rrtica a ys ems _ Cooling Water BI Heat Reserve sa (CW)Pumps Eg,hanger it Potable Cnndt Deaeratnr SCE Hot Water �.Water Heater: g Makeup Water Storage Tank pyygery HVAC CW Re[um Loop mm� Waste Steam .i A B � Euhangers CW Amin� CW Return �Retur E eNc � ogger�cu er ion l 'XZ: 19 QUESTIONS? 'v '20 a . March 17, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 30 of 32 10