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HomeMy WebLinkAbout05.a. Receive update on the Asset Management Program, continued from March 17, 2020 Page 1 of 12 Item 5.a. CENTRAL SAN April 14, 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 [CONTINUED FROM MARCH 17, 2020] 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 April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 10 of 23 Page 2 of 12 �• res „+ ASSET MANAGEMENT ACCOMPLISHMENTS Nitin Goel Senior Engineer Special Projects and Asset Management Group Engineering and Operations Committee Meeting April 14, 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 April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 11 of 23 1 Page 3 of 12 CENTRAL SAN HAS A GEOGRAPHIC INFORMATION SYSTEM (GIS) CENTRIC ASSET MANAGEMENT ECOSYSTEM r:a:Wxks KM InfoNlaSbet Cityworks DYNAC° H draulic Ca Risk Model Asset Maintenance plant Conliul y pacify Model Priorkixed Capital Plan Management System(SCADA) /1 I I �.awW .e5r( Is EnteArcGls �i/' rpdse ® Dati Automation Enterprlse Geodatabases and Map Services — Resaurce Planning CCN Inspection/ Geocortex' canditi.n assesmeM ® aapbe Web Mapping Applications ColdFuslon tape�.e e I pm.m out p I Spare Parts P[G-SMART Management Tool t DSA wcating ManagementK� F Data flow • mt: F— Web hyperlinks mm�.non 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 In Progress 12 Strategic Forecasting In Progress 13 Capital Improvement Program Business Case Evaluations V 14 Update Asset Management Plan In Progress ' a CFNTPAISAN April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 12 of 23 2 Page 4 of 12 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 Condition PF"F Report1Reliability Engineering Pipeline Cleaning Collection System 2 Schedules Optimization •,_ . ASSET Operations MANAGEMENT 3Data Optimization toS Streamline workflow Maintenance 16 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 (PM)work order cycles �. ro° ..° .�. .� . G�. ..,. .� . °. Also, did not have a way to view all assets within a specific process 16 April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 13 of 23 3 Page 5 of 12 EXAMPLE 1 : TOOL FOR CONDITION ASSESSMENT - RELIABILITY ENGINEERING REPORT • To access the tool,go to the Treatment Plant Portal °°�•°••�°^ • 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 © W 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 assists Maintenance Division to maximize Ptrenlre lbMe•eiee ViNam W Mmid.SAO f lip•e W!MIN lnMMM• p1 the useful life of Treatment Plant and Pumping Station assets • Tool assists in filtering assets by process/sub - process/system, asset class, availability of spare assets, availability of spare parts, preventive and/or predictive maintenance programs, and whether a reliability analysis was performed ".'"°° a "" """`_'w' _'""__sa_"�" • Reduces maintenance cost W-;.nn mem _.�m,� �. . ��. .,°,;... • Improves employee safety °"°-"-�� O • Extends remaining useful life of the assets 1 8 CFNTPAI SAN April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 14 of 23 4 Page 6 of 12 EXAMPLE 2: BACKGROUND FOR OPTIMIZING PIPELINE CLEANING SCHEDULE • CSO had over 20,000 cleaning work orders in 2018 1» • Previous method of using Excel spreadsheets and forms for organizing and scheduling cleaning was a time-consuming effort 0 O • Cleaning schedule and location were unevenly distributed . _ • For example: some months have more cleaning = footage scheduled than other 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 • Web GIS application enables CSO staff to view cleaning based on � t �' schedule frequency intervals and by location • Ability to click on each pipe to view "k`TA custom Asset Maintenance Information Report to get insight on how much cleaning is scheduled •„• • "�'r`,� ' each month •� "` C �.,. • Ability to project out seven years • Ability for staff to schedule mains(or groups of mains)to manage ®_„•w-�„• '” distribution of schedules by month „_. • Asset Management Application _ �- San staff to schedule pipes location optimize crew time ' io CFNTPAISAN April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 15 of 23 5 Page 7 of 12 EXAMPLE 2: OPTIMIZATION PIPELINE CLEANING SCHEDULE BENEFITS • Ability to project out seven years Asset Maintenance Information Gr-auily Man MaIMc>•anrc Pr°Jec1e0 FmSages • More effective utilization of staff time ,.u,. •,e.� ,�.,.,, A„• • Reduced vehicle wear-and-tear • Reduced costs& reduced impact on the public a/f%Q1 2,51w r,1.M .. CIFINTIPAISAN EXAMPLE 3: PRESSURE RELIEF AND WYE DEMOTION PROCESS BACKGROUND Prior to this effort, sewer gravity mains pipes were 6U{„l°CA segmented by pressure reliefs and wyes as ` m defining structures in the � P a 4--6 asset registry Example: Pipe Segment between M20 and M18 • There is a Pressure Relief(PR) 19 in- Previously, • Previously, crew would inspect or clean in two -� - separate work orders M20 to PR19 was one work order and PR19 to M18 was a seco - ' April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 16 of 23 6 Page 8 of 12 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 °s�o"'a'"`B�°•'"`°`"�"°" segments and related work orders • Combined over 500 wye-related pipe segments and related work orders • Enhanced GIS data structure - • Streamlined the cleaning and inspection process �- • Resulted in the elimination of unintended duplication of cleaning efforts -- • Decreased the number of work orders cleaning and inspection crews need to open ' 14 CFNTPAISAN April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 17 of 23 7 Page 9 of 12 STEAM PROJECT SCOPE, MAJOR WORKSHOPS, & BUDGET Confirm Detailed . . 'o c't Identifyp ,�,%Caa ires AssessmentsAlternatives (Workshop Date- 01.14.20) , . :�onfirm Project revelop Lifecycle t Costs for Alternatives P-!sign S re-De September 2020) � I ' 15 STEAM PROJECT OVERALL OBJECTIVES As apart of the Steam Project, condition STEAMPR03ECTPHASEI-A55ESSINGTHECONOITIONOF p 1 THE STEAM&AERATION SYSTEM. �. 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 April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 18 of 23 8 Page 10 of 12 VARIOUS LEVELS OF CONDITION ASSESSMENTS WERE PERFORMED TO DETERMINE REMAINING USEFUL LIFE Condition . - can be Level 5— Level 4— Forensic Non- Testing Level 3— Destructive Performance Testing Testing Level 2— Visual Field Inspection Level 1— Review of Age& Expected Life ' 17 AFTER COMPLETING VARIOUS LEVELS OF CONDITION ASSESSMENT, WEIGHTS ARE ASSIGNED TO VARIOUS LEVELS OF CONDITION ASSESSMENT THAT ARE USED FOR DETERMINING REMAINING USEFUL LIFE Condition . - Level 1-Review of Age and 15% 15% 15% 15% Expected Life Level 2-Visual Field 85% 42.5% 42.5% 30% Inspection Level 3- Performance Testing 42.5% 25% Level 4- Non-Destructive 42.5% 30% Evaluation (NDE) Total 100% 100% 100% 100% The assessment scores used a fixed value for Level 1 of 15%,and the weight of unperformed Levels 2-4 assessments were split evenly among the completed Levels 2-4 assessments. i.e. If no Level 3 was completed for an asset,the aggregate score for it was determined by multiplying the Level 1 score by 15%,the Level 2 score by 42.5%(30%+25%/2),and the Level 4 score by 42.5%(30%+25%/2). 49 CFNTPAISAN April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 19 of 23 9 • I ej i i iel DAMON • ' 1 ' • ' • CA Level Condition Years of Life Weight Comments Score Remaining Example: Furnace Waste Heat Boiler ................. ................. a:::.. Estimated . remaining life is>20 years, based on age/visual/NDE :: :::: ::: iS :t :i t :; t..... .. assessment. Consider minor corrective maintenance(cycle chemical = = == """=". improvements and chemical cleaning). • • Lh I A 0 1 a • s� • 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 12 of 12 STEAM SYSTEM ASSETS THAT ARE EVALUATED PART OF STEAM PROJECT Solids . . 5ralm Cenhifuge System Hot lNaier - - Healer Exchanger Sanapltng 9rytern' Copolymer Pumping • Blower : • i hoilerfeedwaterand {ta Boilers) EEeetric 6lowdown amphng L I Feed Systems _ Condenser Blower rrtica Cooling Water Heat Heservo (CW)Pumps _ Exchanger'r pnWhle candL oeaeramr SCa hnt Water -.Water Heaters 8 Makeup Water Storage Tank py -, HVAC CW Return Loop _ Waste Steam .�i A B -nge� E�ah—n . Amin CW Return CW '������ Return E eutrc, E75 cu ogger, er ion .Ery. Rehrm 'ZZ QUESTIONS? r -- zz April 14, 2020 EOPS Regular Committee Meeting Agenda Packet- Page 21 of 23 11