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HomeMy WebLinkAbout5.b. Receive recap of 2022 Innovations Fair Page 1 of 16 Item 5.b. CENTRAL SAN November 1, 2022 TO: ADMINISTRATION COMMITTEE FROM: CHRISTINA GEE, MANAGEMENT ANALYST REVIEWED BY: TEJI O'MALLEY HUMAN RESOURCES AND ORGANIZATIONAL DEVELOPMENT MANAGER SUBJECT: RECEIVE RECAP OF 2022 INNOVATIONS FAIR At the September 21, 2022 Employee Appreciation Picnic, Central San hosted its first in-person Innovations Fair to celebrate employees' creativity by showcasing innovative projects currently in progress or completed in the last two years. Featured projects were selected from nominations submitted by staff, and display booths were created by the innovators. Fair attendees voted for Innovation of the Year, and the winners were as follows: I NNOVATI ON OF THE YEAR: Debris-Catching Device for Maintenance Access Holes Innovators: Tifton Gantt and Loren Reimer(Collection System Operations (CSO)) RUNNER-UP: Improved Effluent with Dissolved Oxygen Set Point Change Innovators: Mike Allen (Plant Operations),Aaron Cortez (Plant Operations), and Michael Cunningham (Special Projects/Planning & Development Services) Other Featured Innovations with booth displays at the fair included the following: • 75th Anniversary Experience Innovators: Emily Barnett, Chris Carpenter, Kelsey Lansang, Ben Lavender, Ann Vallee, Joe Zumbo, retiree Charles Waltmire, and former intern Zoie Campbell (Communications) • Phone System Replacement Innovators: DmitryAbramov, Damon Dun, Matt Hart, Tim Hiteshew, Charles Mallory, Joseph Smith, George Solivar, Jose Vega, and retiree John Huie (Information Technology(IT)) • Tertiary Membrane Filtration Pilot Innovators:Amanda Cauble and Dan Frost(Planning&Applied Research) • UV Resource Planning Dashboard Innovators: Khae Bohan (Asset Management), Mike Matthews (Asset Management), Neil Meyer(Plant Maintenance), Ian Morales (Asset Management), Jon Nicolaus (Plant Maintenance), and Carl Von Steffen (Asset Management) November 1, 2022 Regular ADM IN Committee Meeting Agenda Packet- Page 45 of 62 Page 2 of 16 A poster board catalogued Recent Innovations in the Mechanical Maintenance Shop: • Heat Exchange Flushing Cart Innovator:Anthony Smith (Mechanical Shop) • Return Activated Sludge Pump Improvements Innovators: Kenny Rosenstiel and Brian Walters (Mechanical Shop) • Diagnosing, Replacing, and Repairing the Furnace No. 2 Gearbox Using Motion Amplification Technology Innovators: Shaun Mockel, Anthony Smith, and Brian Walters (Mechanical Shop) Finally, the Incubator Booth showcased two innovations currently in progress: • Digital Operator Rounds Sheets Innovators:Ashley Freeman (CSO), Nick Hansen (Plant Operations), Neil Meyer(Plant Maintenance), and Ian Morales (Asset Management) • Handheld Device to Collect Household Hazardous Waste Collection Facility(HHWCF) Visitor Data Innovators: DmitryAbramov(IT), Dennis Chebotarev(IT), Dave Wyatt(HHWCF), and Winston Ingram (HHWCF) Staff would like to thank everyone who nominated projects, the innovators, staff who visited the fair, the Buildings & Grounds team for assisting with the setup and takedown, Jimmie Castillo in the Reprographics Service Center for printing the materials for the fair, Human Resources and Organizational Development Manager Teji O'Malley and General Manager Roger S. Bailey for supporting the fair, and to the Central San Leadership Team and Board of Directors for fostering innovation throughout the organization. At the Committee meeting, staff will present a recap of the fair as well as information on the featured projects via the attached presentation. Strategic Plan re-In GOAL ONE: Customer and Community Strategy 1—Deliver high-quality customer service GOAL THREE: Workforce Diversity and Development Strategy 3- Retain skilled workers by investing in resources and opportunities for all employees to grow and thrive GOAL FOUR: Governance and Fiscal Responsibility Strategy 3- Maintain financial stability and sustainability GOAL SIX: Infrastructure Reliability Strategy 1 - Manage assets optimally GOAL SEVEN: Innovation and Agility Strategy 1 - Leverage data analytics to become a more efficient utility, Strategy 2- Implement organization-wide optimization, Strategy 3- Be adaptable, resilient and responsive November 1, 2022 Regular ADM IN Committee Meeting Agenda Packet- Page 46 of 62 Page 3 of 16 ATTACHMENTS: 1. Presentation November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 47 of 62 Page 4 of 16 November 1,2022 2022 s Innovations Fair Administration Committee Meeting Christina Gee Management Analyst 4 f 1 Fair k Nominations solicited from staff I Vis lt:he Incubator Booth to see in-progress projects j`- and suggest ideas to make us more innovative Projects showcased by category Mecca the Innovations in Visrt the Featured Innovation booths and Mechanical VOTE for Your favorite one Maintenance Featured Innovations display Recent innovations in Mechanical Maintenance Incubator Booth Live voting at the fair to select winners from Featured Innovations i z November 1, 2022 Regular ADM IN Committee Meeting Agenda Packet- Page 48 of 62 1 Page 619Vr/2022 INNOVATION OF THE YEAR: Debris-Catching Device for Maintenance Access Holes Innovators: Tifton Gantt (Collection System Operations (CSO)) and Loren Reimer(CSO) 3 Challenge Adjusting maintenance access hole castings and covers creates concrete debris that falls . into a makeshift device or into the channel Requires confined space entry or a vac truck c. •. • r Innovation: _ Debris-catching device Catches the debris at an easily-reachable level Is adjustable for differently sized access maintenance access holes Easy to carryr t� Only cost:a signpost(everything to make the device was found at CSO) {1' 4 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 49 of 62 2 Page agVJ4/2022 RUNNER-UP: _ Improved Effluent with Dissolved Oxygen (DO) } Set Point Change Innovators: - Mike Allen (Plant Operations), Aaron Cortez (Plant Operations), and Michael Cunningham (Special Projects/ Planning) F .. ,:r• 5 Challenge • Aeration equipment is aging,and air distribution control is challenging f • High turbidity(low clarity)events were increasing in frequency and duration ` R. • Requires increased Operator attention • Makes ultraviolet(UV)and recycled water processes less efficient # • Shutdowns for preventative maintenance work were more challenging to schedule �:1i1 s Innovation: Changing the set point of the DO target • Redistributed air within Central San's 8.4 million gallon aeration tanks • Bumped up DO target at the meter's controlling air flow to the first half of the tanks from a typical industry value of 2 to 3 mg/L • Results • Stabilized and improved effluent quality by decreasing turbidity(increasing clarity) • Less UV disinfection lamps need to be in service,reducing electricity demand and maintenance for cleaning and lamp replacement • Easier and more efficient to operate recycled water treatment processes(higher water quality,which can help reduce chemical usage) • Lower nitrogen being observed in effluent data from summer 2022 • Will potentially help effluent quality stability during future shutdowns needed for capital projects 6 6 November 1, 2022 Regular ADM IN Committee Meeting Agenda Packet- Page 50 of 62 3 Page 710VJ4/2022 Aeration System Overview " A ■ Aeration basins One actuator controls r i "I ! i (Air Added) �Iy air per pass($total) 4 basins each L IJ I J (2 Passes per basin) 41 down comers M per pass(88 total) •t EM( MUL f ►-gLLU ' mu d"Ioak in)x fopl-b—e(8 total] r 7 Treatment Plant Effluent Turbidity (lower turbidity indicates better clarity) Set WM change[.8q"19L i is — i i 8 Y_ 9 - 4 ®r 1 W—ly Awmpe b"a;SA M AWaga■mer.M NTU 8 8 November 1, 2022 Regular ADM IN Committee Meeting Agenda Packet- Page 51 of 62 4 Page 810vvo, 022 Featured Innovation: 75th Anniversary Experience Innovators: Emily Barnett, Ben Lavender, Zoie Campbell (former intern) (not pictured) Ann Vallee, Chris Carpenter, Charles Waltmire (retiree), and Kelsey Lansang, Joe Zumbo (all in Communication Services) 9 Challenge Celebrate Central San's 75th anniversary with a public"open house"event during a pandemic Since its launch Innovation: a year ago, there have been 75th Anniversary Experience customer website >11,000 page views and 360-degree interactive website(75th.centralsan.org)with a guided facilities tour,a 13,500 hotspot clicks learning hub with hands-on science activities for kids,videos,photo galleries,historical across the site. facts and images,and customer information on how to protect their pipes,safely Additionally, dispose of household hazardous waste,and get free recycled water for their gardens >20 virtual tours Enhances accessibility for tours for>900 participants Facilitates customer engagement of all ages _ .x, have been hosted Has been used to recruit and tit ; ,"' using the site. educate future wastewater workers - - — - 10 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 52 of 62 5 Page gLQVr/2022 Featured Innovation: - Phone System Replacement . s Innovators: _ Dmitry Abramov, Charles Mallory, Damon Dun, Joseph Smith, TFEAMS Matt Hart, George Solivar, and Tim Hiteshew, Jose Vega John Huie (retiree) (all in Information Technology (IT)) COMING 05, 11 •'a � � V Challenger ` Dated Avaya phone system lacked modern communication and R productivity features Innovation: Teams-based phone system �. Culmination of three-year search considering different options Based on and integrated with Teams Staff can be more responsive while working off-site Helps maintain high customer service levels q ant uuHe Image from https:/Iuwm.edu/news/calling-features-added-to-microsoft-teams/ 12 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 53 of 62 6 Page "f1l2022 Featured Innovation: Tertiary Membrane Filtration Pilot Innovators: + r Amanda Cauble (Planning &Applied Research) and Dan Frost (Planning &Applied Research) F• 13 Challenge Need to determine what filtration method will best meet Title 22 recycled .� water regulations and facilitate future advanced recycled water �� a opportunities for Central San -_ Innovation: Pilot project • Tested three membrane manufacturers in parallel • Operated a dual-stage reverse osmosis skid • Ran concurrently with Phase 1A of the Filter Plant Improvements Project, where staff changed the media in one of the four filter cells for comparison • Required 24/7 operation over six months,with staff performing operator h checklists,water quality tests,and membrane chemical cleans;observing " performance trends;and completing maintenance and repairs • Decommissioned in July 2022 1 • Findings will help determine optimal operating parameters and how those might translate in full-scale costs • Business case evaluation will be updated to determine best steps for the Filter Plant improvements to further Central San's mission of protecting the environment,while being fiscally responsible 14 14 November 1, 2022 Regular ADM IN Committee Meeting Agenda Packet- Page 54 of 62 7 Page 11Qf1TAu,'2022 Featured Innovation: UV Resource Planning Dashboard Innovators: r Khae Bohan (Asset Management), Mike Matthews (Asset Management), Neil Meyer (Plant Maintenance), Ian Morales (Asset Management), F Jon Nicolaus (Plant Maintenance), and Carl Von Stetten (Asset Management) s P�l l , 15 Challenge . The planning of UV re-lamp is a pen and binder process Operations staff informs Maintenance which UV lamp banks are approaching 10,000 hours or vice versa Maintenance staff calls Warehouse to ensure UV bulbs and quartz sleeves availability Staff creates work order and plans work activity based on staff availability A o-.A 1 Innovation: _ UV Resource Planning Dashboard ' rowThe planning of UV re-lamp is a digital process r� Data comes directly from SCADA*historian database, Cityworks asset management,and Oracle warehouse Scheduling/planning is more efficient Near real-time data is viewable from anywhere (runtime and UV Bank data is refreshed every five minutes and Oracle is refreshed hourly) *SCADA=Supervisory Control and Data Acquisition 16 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 55 of 62 8 Page "f1TAu,12022 Recent Innovations in the Mechanical Maintenance Shop: +' Heat Exchanger Flushing Cart _ Innovator: Anthony Smith (Mechanical Shop) Challenge Heat exchangers run process water through tubes to keep critical equipment from overheating Over time,the water leaves residue inside the walls of the tubes,reducing efficiency or eventually requiring replacement of the exchanger Innovation This cart—made in house—flushes the material out,allowing the exchangers to cool the equipment they serve for many more years 17 Recent Innovations in the Mechanical Maintenance Shop: Diagnosing, Replacing, and Repairing the Furnace No. 2 Gearbox Using Motion Amplification Technology Innovators: Motion Vectors Shaun Mockel,Anthony Smith, and Brian Walters (all in the Mechanical Shop) i Challenge } Operations noticed an oil leak and a crack when bringing the furnace online. CraA in gearbox foot Innovation By filming the gearbox in slow motion using motion amplification technology,technicians could see what was not visible to the naked eye:the gearbox was rocking side to side and cracking its case The gearbox and pinion gear was changed;then,technicians noticed a potential"soft foot"(void between mounting surfaces which can cause stress and deformation)on the rebuilt gearbox. Staff step shimmied each foot to minimize any soft foot issue Staff confirmed the fix was complete by taking follow-up videos 18 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 56 of 62 9 Page "f1TAu,12022 Motion Amplification Video (screenshots in previous slide) 19 Recent Innovations in the Mechanical Maintenance Shop: Return Activated Sludge (RAS) Pump Improvements Innovators: Kenny Rosenstiel and Brian Walters (both in the Mechanical Shop) Replaced v-belt with a cog belt (improving power transmission) Greased the bearings instead of using oil (increasing reliability) Converted mechanical seal from split to cartridge style (reducing leakage and making impeller adjustment easier) Chromed pump shaft surface (preventing corrosion) - Split the 60 lb.guard in half for easier access (making maintenance a one-person job) 20 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 57 of 62 10 Page "f1TAu,12022 ti Incubator Booth: Digital Operator Rounds Sheets �c +- I t� Innovators: Ashley Freeman (CSO), „• y \ ` Nick Hansen (Plant Operations), �l Neil Meyer (Plant Maintenance), and Ian Morales (Asset Management) ' Uvj. . 21 Challenge Plant Operators perform "rounds" every day to gather data Up to 3,300 data points on 18 sheets of paper are collected and copied by hand for the Control Room Less than 8%of the data that is written/collected is stored electronically_„ Innovation in progress: Digitizing Operator Rounds Sheets Transferred the sheet templates into Cityworks . Operators are currently beta testing the digitized IL _ process on mobile devices -- Ability to import and export data in a central system Rounds will be a more efficient and paperless process Templates are easy to edit 22 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 58 of 62 11 Page "f1TAu,12022 Incubator Booth: - Handheld Device to Collect Household Hazardous Waster Collection Facility (HHWCF) Visitor Data Innovators: Dmitry Abramov (IT), d Dennis Chebotarev (IT), Winston Ingram (HHWCF), and Dave Wyatt (HHWCF) 23 Challenge Over 74,000 drivers licenses (DL) are scanned annually Technicians take the DLs and enter data into an aging system by hand Innovation in progress: ` Handheld Device to Collect Visitor Data Identified and piloted a new, compact device that can scan a DL and collect data for improved record-keeping and reporting Can be used interchangeably at either facility Staff is now using the new devices full time The second phase of the project- reporting and data visualization- is currently in development 24 November 1, 2022 Regular ADMIN Committee Meeting Agenda Packet- Page 59 of 62 12 Page IW�� 2a22 Acknowledgements Project Nominators Innovators Fair Visitors Buildings&Grounds Crew Jimmie Castillo in the Reprographics Service Center Teji O'Malley Roger S. Bailey(notably, for taking several of the photographs in this presentation) Leadership Team Board of Directors 4 25 26 November 1, 2022 Regular ADM IN Committee Meeting Agenda Packet- Page 60 of 62 13